Ford - Escape 4wd - Workshop Manual - 2002 - 2002

Factory Workshop Manual Make Ford Model Escape 4wd Engine and year V6-182 3.0L VIN 1 SFI (2002) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Ford directs the user to follow P1121 For diagnosis of code P0068, refer to P1121 in the following chart P071x Thru P1125 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 13 P0100 - P0104: Testing and Inspection P0103 For diagnosis of code P0103 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 18 P0105 - P0109: Testing and Inspection P0107 For diagnosis of code P0107 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 19 P0105 - P0109: Testing and Inspection P0108 For diagnosis of code P0108 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 20 P0105 - P0109: Testing and Inspection P0109 For diagnosis of code P0109 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 25 P0110 - P0114: Testing and Inspection P0113 For diagnosis of code P0113 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 30 P0115 - P0119: Testing and Inspection P0117 For diagnosis of code P0117 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 31 P0115 - P0119: Testing and Inspection P0118 For diagnosis of code P0118 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 36 P0120 - P0124: Testing and Inspection P0122 For diagnosis of code P0122 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 37 P0120 - P0124: Testing and Inspection P0123 For diagnosis of code P0123 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 42 P0125 - P0129: Testing and Inspection P0128 For diagnosis of code P0128 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 47 P0130 - P0134: Testing and Inspection P0132 For diagnosis of code P0132 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 48 P0130 - P0134: Testing and Inspection P0133 For diagnosis of code P0133 refer to chart P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 53 P0135 - P0139: Testing and Inspection P0136 For diagnosis of code P0136 refer to chart P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 54 P0135 - P0139: Testing and Inspection P0138 For diagnosis of code P0138 refer to chart P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 65 P0150 - P0154: Testing and Inspection P0152 For diagnosis of code P0152 refer to chart P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 66 P0150 - P0154: Testing and Inspection P0153 For diagnosis of code P0153 refer to chart P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 71 P0155 - P0159: Testing and Inspection P0156 For diagnosis of code P0156 refer to chart P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 72 P0155 - P0159: Testing and Inspection P0158 For diagnosis of code P0158 refer to chart P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 80 P0170 - P0174: Testing and Inspection P0172 For diagnosis of code P0172 refer to chart P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 81 P0170 - P0174: Testing and Inspection P0174 For diagnosis of code P0174 refer to chart P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 89 P0180 - P0184: Testing and Inspection P0181 For diagnosis of code P0181 refer to chart P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 90 P0180 - P0184: Testing and Inspection P0183 For diagnosis of code P0183 refer to chart P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0133 Thru P0190 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 95 P0190 - P0194: Testing and Inspection P0191 For diagnosis of code P0191 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 96 P0190 - P0194: Testing and Inspection P0192 For diagnosis of code P0192 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 97 P0190 - P0194: Testing and Inspection P0193 For diagnosis of code P0193 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 103 P0200 - P0204: Testing and Inspection P0202 For diagnosis of code P0202 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 104 P0200 - P0204: Testing and Inspection P0203 For diagnosis of code P0203 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 105 P0200 - P0204: Testing and Inspection P0204 For diagnosis of code P0204 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 110 P0205 - P0209: Testing and Inspection P0206 For diagnosis of code P0206 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 111 P0205 - P0209: Testing and Inspection P0207 For diagnosis of code P0207 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 112 P0205 - P0209: Testing and Inspection P0208 For diagnosis of code P0208 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 113 P0205 - P0209: Testing and Inspection P0209 For diagnosis of code P0209 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 118 P0210 - P0214: Testing and Inspection P0211 For diagnosis of code P0211 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 119 P0210 - P0214: Testing and Inspection P0212 For diagnosis of code P0212 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 124 P0230 - P0234: Testing and Inspection P0231 For diagnosis of code P0231 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 125 P0230 - P0234: Testing and Inspection P0232 For diagnosis of code P0232 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 131 P0300 - P0304: Testing and Inspection P0301 For diagnosis of code P0301 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 132 P0300 - P0304: Testing and Inspection P0302 For diagnosis of code P0302 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 133 P0300 - P0304: Testing and Inspection P0303 For diagnosis of code P0303 refer to chart P0191 Thru P0303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 134 P0300 - P0304: Testing and Inspection P0304 For diagnosis of code P0304 refer to chart P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 139 P0305 - P0309: Testing and Inspection P0306 For diagnosis of code P0306 refer to chart P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 140 P0305 - P0309: Testing and Inspection P0307 For diagnosis of code P0307 refer to chart P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 141 P0305 - P0309: Testing and Inspection P0308 For diagnosis of code P0308 refer to chart P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 149 P0315 - P0319: Testing and Inspection P0316 For diagnosis of code P0316 refer to chart P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 157 P0325 - P0329: Testing and Inspection P0326 For diagnosis of code P0326 refer to chart P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 162 P0330 - P0334: Testing and Inspection P0331 For diagnosis of code P0331 refer to chart P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 170 P0350 - P0354: Testing and Inspection P0351 For diagnosis of code P0351 refer to chart P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 171 P0350 - P0354: Testing and Inspection P0352 For diagnosis of code P0352 refer to chart P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 172 P0350 - P0354: Testing and Inspection P0353 For diagnosis of code P0353 refer to chart P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 173 P0350 - P0354: Testing and Inspection P0354 For diagnosis of code P0354 refer to chart P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 178 P0355 - P0359: Testing and Inspection P0356 For diagnosis of code P0356 refer to chart P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 179 P0355 - P0359: Testing and Inspection P0357 For diagnosis of code P0357 refer to chart P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 180 P0355 - P0359: Testing and Inspection P0358 For diagnosis of code P0358 refer to chart P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 181 P0355 - P0359: Testing and Inspection P0359 For diagnosis of code P0359 refer to chart P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0304 Thru P0360 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > P0401 P0400 - P0404: Testing and Inspection P0401 For diagnosis of code P0401 refer to chart P0400 Thru P0500 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > P0401 > Page 190 P0400 - P0404: Testing and Inspection P0402 For diagnosis of code P0402 refer to chart P0400 Thru P0500 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0400 Thru P0500 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 195 P0405 - P0409: Testing and Inspection P0406 For diagnosis of code P0406 refer to chart P0400 Thru P0500 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0400 Thru P0500 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 200 P0410 - P0414: Testing and Inspection P0412 For diagnosis of code P0412 refer to chart P0400 Thru P0500 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0400 Thru P0500 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0400 Thru P0500 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 211 P0440 - P0444: Testing and Inspection P0443 For diagnosis of code P0443 refer to chart P0400 Thru P0500 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Ford directs the user to follow P1451 For diagnosis of code P0446, refer to P1451 in the following chart P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0400 Thru P0500 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 219 P0450 - P0454: Testing and Inspection P0452 For diagnosis of code P0452 refer to chart P0400 Thru P0500 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 220 P0450 - P0454: Testing and Inspection P0453 For diagnosis of code P0453 refer to chart P0400 Thru P0500 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 225 P0455 - P0459: Testing and Inspection P0457 For diagnosis of P0457 refer to the system experiencing the problem. Computers and Control Systems P0400 Thru P0500 If there is no link in the chart then: - 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 Instrument Cluster Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 226 DTC Index P0457 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0400 Thru P0500 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 231 P0460 - P0464: Testing and Inspection P0461 For diagnosis of code P0461 refer to chart P0400 Thru P0500 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 - P0484: Testing and Inspection For diagnosis of code P0480 refer to chart P0400 Thru P0500 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0500 refer to chart P0400 Thru P0500 NOTE 12: Vehicle speed information is provided by the Anti-lock Brake System (ABS). If there is no link in the chart then: - 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 ABS diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 240 P0500 - P0504: Testing and Inspection P0501 For diagnosis of code P0501 refer to chart P0501 Thru P0708 NOTE 12: Vehicle speed information is provided by the Anti-lock Brake System (ABS). If there is no link in the chart then: - 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 ABS diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 241 P0500 - P0504: Testing and Inspection P0503 For diagnosis of code P0503 refer to chart P0501 Thru P0708 NOTE 12: Vehicle speed information is provided by the Anti-lock Brake System (ABS). If there is no link in the chart then: - 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 ABS diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0501 Thru P0708 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 246 P0505 - P0509: Testing and Inspection P0506 Ford directs the user to follow P1507 For diagnosis of code P0506, refer to P1507 in the following chart P1502 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 247 P0505 - P0509: Testing and Inspection P0507 Ford directs the user to follow P1506 For diagnosis of code P0507, refer to P1506 in the following chart P1502 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Ford directs the user to follow P1504 For diagnosis of code P0511, refer to P1504 in the following chart P1502 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0501 Thru P0708 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0501 Thru P0708 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 258 P0550 - P0554: Testing and Inspection P0553 For diagnosis of code P0553 refer to chart P0501 Thru P0708 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 chart P0501 Thru P0708 NOTE 11: The Vehicle ID block (VID) needs to be reprogrammed. For instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 264 P0600 - P0604: Testing and Inspection P0603 For diagnosis of code P0603 refer to chart P0501 Thru P0708 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 chart P0501 Thru P0708 NOTE 14: Be sure to check for aftermarket performance products before replacing 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 269 P0605 - P0609: Testing and Inspection P0606 For diagnosis of code P0606 refer to chart P0501 Thru P0708 NOTE 14: Be sure to check for aftermarket performance products before replacing 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Vechicles With A Constant Control Relay Module (CCRM): Ford directs the user to follow P1460 For diagnosis of code P0645, refer to P1460 in the following chart P1405 Thru P1501 All Other Vehicles: For diagnosis of code P0645 refer to chart Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 273 P0501 Thru P0708 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P0501 Thru P0708 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 279 P0700 - P0704: Testing and Inspection P0704 For diagnosis of code P0704 refer to chart P0501 Thru P0708 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 B2512 - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 284 P0705 - P0709: Testing and Inspection P0707 For diagnosis of code P0707 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 285 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 286 P0705 - P0709: Testing and Inspection P0708 For diagnosis of code P0708 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 287 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 292 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 293 P0710 - P0714: Testing and Inspection P0713 For diagnosis of code P0713 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 294 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 299 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 300 P0715 - P0719: Testing and Inspection P0717 For diagnosis of code P0717 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 301 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 302 P0715 - P0719: Testing and Inspection P0718 For diagnosis of code P0718 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 303 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P071x Thru P1125 If there is no link in the chart then: - 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 Note: "x" = any number 0 thru 9 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 308 P0720 - P0724: Testing and Inspection Automatic Transmission P0720 For diagnosis of code P0720 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 309 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 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 310 - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 311 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 312 Inspection Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 317 - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 318 P0730 - P0734: Testing and Inspection P0732 For diagnosis of code P0732 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 319 - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 320 P0730 - P0734: Testing and Inspection P0733 For diagnosis of code P0733 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 321 - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 322 P0730 - P0734: Testing and Inspection P0734 For diagnosis of code P0734 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 323 - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 328 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 329 P0740 - P0744: Testing and Inspection P0741 For diagnosis of code P0741 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 330 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 331 P0740 - P0744: Testing and Inspection P0743 For diagnosis of code P0743 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 332 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 337 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 338 P0750 - P0754: Testing and Inspection P0751 For diagnosis of code P0751 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 339 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 340 P0750 - P0754: Testing and Inspection P0753 For diagnosis of code P0753 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 341 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 346 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 347 P0755 - P0759: Testing and Inspection P0756 For diagnosis of code P0756 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 348 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 349 P0755 - P0759: Testing and Inspection P0758 For diagnosis of code P0758 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 350 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P071x Thru P1125 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P071x Thru P1125 NOTE 1: DTC P1000 is ignored in KOEO and KOER Self-Test. Disregard the DTC P1000 and continure as directed. If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 360 P1000 - P1004: Testing and Inspection P1001 For diagnosis of code P1001 refer to chart P071x Thru P1125 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P071x Thru P1125 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 366 P1100 - P1104: Testing and Inspection P1101 For diagnosis of code P1101 refer to chart P071x Thru P1125 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > P1112 P1110 - P1114: Testing and Inspection P1112 For diagnosis of code P1112 refer to chart P071x Thru P1125 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > P1112 > Page 371 P1110 - P1114: Testing and Inspection P1114 For diagnosis of code P1114 refer to chart P071x Thru P1125 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > P1115 P1115 - P1119: Testing and Inspection P1115 For diagnosis of code P1115 refer to chart P071x Thru P1125 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > P1115 > Page 376 P1115 - P1119: Testing and Inspection P1116 For diagnosis of code P1116 refer to chart P071x Thru P1125 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > P1115 > Page 377 P1115 - P1119: Testing and Inspection P1117 For diagnosis of code P1117 refer to chart P071x Thru P1125 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P071x Thru P1125 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 382 P1120 - P1124: Testing and Inspection P1121 For diagnosis of code P1121 refer to chart P071x Thru P1125 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 383 P1120 - P1124: Testing and Inspection P1124 For diagnosis of code P1124 refer to chart P071x Thru P1125 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P071x Thru P1125 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 388 P1125 - P1129: Testing and Inspection P1127 For diagnosis of code P1127 refer to chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 389 P1125 - P1129: Testing and Inspection P1128 For diagnosis of code P1128 refer to chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 390 P1125 - P1129: Testing and Inspection P1129 For diagnosis of code P1129 refer to chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 395 P1130 - P1134: Testing and Inspection P1131 For diagnosis of code P1131 refer to chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 396 P1130 - P1134: Testing and Inspection P1132 For diagnosis of code P1132 refer to chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 401 P1135 - P1139: Testing and Inspection P1138 For diagnosis of code P1138 refer to chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 406 P1150 - P1154: Testing and Inspection P1151 For diagnosis of code P1151 refer to chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 407 P1150 - P1154: Testing and Inspection P1152 For diagnosis of code P1152 refer to chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 412 P1155 - P1159: Testing and Inspection P1158 For diagnosis of code P1158 refer to chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 417 P1165 - P1169: Testing and Inspection P1169 For diagnosis of code P1169 refer to chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 422 P1180 - P1184: Testing and Inspection P1181 For diagnosis of code P1181 refer to chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 423 P1180 - P1184: Testing and Inspection P1183 For diagnosis of code P1183 refer to chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 424 P1180 - P1184: Testing and Inspection P1184 For diagnosis of code P1184 refer to chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 B2512 - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1225 - P1229, ( P1226 P1227 P1228 1225 1226 1227 1228 1229 ) > System Information > System Diagnosis P1225 - P1229: Testing and Inspection For diagnosis of code P1229 refer to chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 436 P1230 - P1234: Testing and Inspection P1233 For diagnosis of code P1233 refer to chart P1233 Thru P1401 NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics. If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 437 P1230 - P1234: Testing and Inspection P1234 For diagnosis of code P1234 refer to chart P1233 Thru P1401 NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics. If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 442 P1235 - P1239: Testing and Inspection P1236 For diagnosis of code P1236 refer to chart P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 443 P1235 - P1239: Testing and Inspection P1237 For diagnosis of code P1237 refer to chart P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 444 P1235 - P1239: Testing and Inspection P1238 For diagnosis of code P1238 refer to chart P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 452 P1245 - P1249: Testing and Inspection P1246 For diagnosis of P1246 refer to the system experiencing the problem. Computers and Control Systems Refer to Pinpoint Test HY1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/Tests HY: Generator/Regulator System If there is no link in the chart then: - 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 463 P1285 - P1289: Testing and Inspection P1288 For diagnosis of code P1288 refer to chart P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 464 P1285 - P1289: Testing and Inspection P1289 For diagnosis of code P1289 refer to chart P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 482 P1380 - P1384: Testing and Inspection P1381 For diagnosis of code P1381 refer to chart P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 483 P1380 - P1384: Testing and Inspection P1383 For diagnosis of code P1383 refer to chart P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 489 P1400 - P1404: Testing and Inspection P1401 For diagnosis of code P1401 refer to chart P1233 Thru P1401 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 494 P1405 - P1409: Testing and Inspection P1406 For diagnosis of code P1406 refer to chart P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 495 P1405 - P1409: Testing and Inspection P1408 For diagnosis of code P1408 refer to chart P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 496 P1405 - P1409: Testing and Inspection P1409 For diagnosis of code P1409 refer to chart P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 P1410 - P1414: Testing and Inspection P1413 For diagnosis of code P1413 refer to chart P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 501 P1410 - P1414: Testing and Inspection P1414 For diagnosis of code P1414 refer to chart P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1430 - P1434, ( P1431 P1432 P1433 1430 1431 1432 1433 1434 ) > System Information > System Diagnosis P1430 - P1434: Testing and Inspection For diagnosis of code P1432 refer to chart P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 509 P1435 - P1439: Testing and Inspection P1437 For diagnosis of code P1437 refer to chart P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1405 Thru 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 Evaporative Emissions System Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 517 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 518 P1450 - P1454: Testing and Inspection P1451 For diagnosis of code P1451 refer to chart P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 523 P1460 - P1464: Testing and Inspection P1461 For diagnosis of code P1461 refer to chart P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 524 P1460 - P1464: Testing and Inspection P1462 For diagnosis of code P1462 refer to chart P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 525 P1460 - P1464: Testing and Inspection P1463 For diagnosis of code P1463 refer to chart P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 526 P1460 - P1464: Testing and Inspection P1464 For diagnosis of P1464 refer to the system experiencing the problem. Computers and Control Systems P1405 Thru 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 Heating and Air Conditioning Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 527 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 538 P1475 - P1479: Testing and Inspection P1479 For diagnosis of code P1479 refer to chart P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 544 P1500 - P1504: Testing and Inspection P1501 For diagnosis of code P1501 refer to chart P1405 Thru 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 545 P1500 - P1504: Testing and Inspection P1502 For diagnosis of code P1502 refer to chart P1502 Thru P1640 NOTE 12: Vehicle speed information is provided by the Anti-lock Brake System (ABS). If there is no link in the chart then: - 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 ABS diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 546 P1500 - P1504: Testing and Inspection P1504 For diagnosis of code P1504 refer to chart P1502 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 551 P1505 - P1509: Testing and Inspection P1507 For diagnosis of code P1507 refer to chart P1502 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 556 P1515 - P1519: Testing and Inspection P1517 For diagnosis of code P1517 refer to chart P1502 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 557 P1515 - P1519: Testing and Inspection P1518 For diagnosis of code P1518 refer to chart P1502 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 558 P1515 - P1519: Testing and Inspection P1519 For diagnosis of code P1519 refer to chart P1502 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 566 P1535 - P1539: Testing and Inspection P1538 For diagnosis of code P1538 refer to chart P1502 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1605 - P1609, ( P1606 P1607 P1608 1605 1606 1607 1608 1609 ) > System Information > System Diagnosis P1605 - P1609: Testing and Inspection For diagnosis of code P1605 refer to chart P1502 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Thru P1640 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 chart P1502 Thru P1640 NOTE 11: The Vehicle ID block (VID) needs to be reprogrammed. For instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 584 P1635 - P1639: Testing and Inspection P1636 For diagnosis of code P1636 refer to chart P1502 Thru P1640 NOTE 18: DTC P1636 indicates the PCM has lost communication with the Inductive Signature Chip. Replace PCM. If replacement is necessary refer to Flash Electically 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 585 P1635 - P1639: Testing and Inspection P1639 For diagnosis of code P1639 refer to chart P1502 Thru P1640 NOTE 11: The Vehicle ID block (VID) needs to be reprogrammed. For instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1641 Thru P179x If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1641 Thru P179x If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 593 P1650 - P1654: Testing and Inspection P1651 For diagnosis of code P1651 refer to chart P1641 Thru P179x If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 599 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 600 P1700 - P1704: Testing and Inspection P1703 For diagnosis of code P1703 refer to chart P1641 Thru P179x If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Manual Transmission For diagnosis of code P1705 refer to chart P1641 Thru P179x If there is no link in the chart then: - 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 Automatic Transmission For diagnosis of code P1705 refer to chart Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 605 If there is no link in the chart then: - 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 606 P1705 - P1709: Testing and Inspection P1706 For diagnosis of code P1706 refer to chart DTC Index B2512 - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 607 P1705 - P1709: Testing and Inspection P1709 For diagnosis of code P1709 refer to chart P1641 Thru P179x If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 612 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 613 P1710 - P1714: Testing and Inspection P1713 For diagnosis of code P1713 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 614 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 615 P1710 - P1714: Testing and Inspection P1714 For diagnosis of code P1714 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 616 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 621 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 622 P1715 - P1719: Testing and Inspection P1718 For diagnosis of code P1718 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 623 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 628 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 629 P1740 - P1744: Testing and Inspection P1743 For diagnosis of code P1743 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 630 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 631 P1740 - P1744: Testing and Inspection P1744 For diagnosis of code P1744 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 632 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 637 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 638 P1745 - P1749: Testing and Inspection P1747 For diagnosis of code P1747 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 639 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 643 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 647 - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 651 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P1641 Thru P179x If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 656 P1780 - P1784: Testing and Inspection P1781 For diagnosis of code P1781 refer to chart P1641 Thru P179x If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 661 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 662 P1785 - P1789: Testing and Inspection P1789 For diagnosis of code P1789 refer to chart If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 663 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 P18xx Thru P2198, Pxxxx If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Ford directs the user to follow P1131 For diagnosis of code P2195, refer to P1131 in the following chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 673 P2195 - P2199: Testing and Inspection P2196 Ford directs the user to follow P1132 For diagnosis of code P2196, refer to P1132 in the following chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 674 P2195 - P2199: Testing and Inspection P2197 Ford directs the user to follow P1151 For diagnosis of code P2197, refer to P1151 in the following chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 675 P2195 - P2199: Testing and Inspection P2198 Ford directs the user to follow P1152 For diagnosis of code P2198, refer to P1152 in the following chart P1127 Thru P1232 If there is no link in the chart then: - 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 682 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 683 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 684 View 151-39 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 685 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 686 Accessory Delay Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 687 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Locations View 151-38 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Locations > Page 694 Accessory Relay (Audio, Instrument Cluster, GEM, & Mirrors) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Locations > Page 695 Audio Control Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Locations > Page 696 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications Multifunction Electronic Control Modules: Specifications Generic Electronic Module (GEM) Nuts ........................................................................................................................................................ 12 Nm 9 Lb-In Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications > Page 700 View 151-18 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 703 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 704 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 705 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 706 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 707 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 708 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 709 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 710 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 711 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Multifunction Electronic Control Modules: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 714 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 715 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 716 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 717 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 718 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 719 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 720 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 721 Multifunction Electronic Control Modules: Connector Views Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 722 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 59-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 723 Diagram 59-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 724 Diagram 59-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description Multifunction Electronic Control Modules: Description and Operation System Description 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description > Page 727 Multifunction Electronic Control Modules: Description and Operation Principles of Operation (How Does It Work?) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Multifunction Electronic Control Modules: Initial Inspection and Diagnostic Overview 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. ^ 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 Vehicle System to continue diagnostics. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 730 Multifunction Electronic Control Modules: Diagnostic Trouble Code Tests and Associated Procedures DTC Index B1217 - B1304 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 731 DTC Index B1309 - B2141 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 732 DTC Index B2425 - C1962 .. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 733 Symptom Chart Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 734 Multifunction Electronic Control Modules: Pinpoint Tests A1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 735 A1 - A3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 736 A3 - A5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 737 A5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Page 738 Multifunction Electronic Control Modules: Service and Repair Generic Electronic Module (GEM) REMOVAL 1. Disconnect the battery ground cable. 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Page 739 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Page 740 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations View 151-21 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 754 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 755 Sunroof / Moonroof Module: Service and Repair REMOVAL 1. Remove the headliner. 2. Remove the roof 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 765 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 766 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 767 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 768 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 769 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 770 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 771 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 772 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 773 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 774 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 775 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 776 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 777 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 778 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 779 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 780 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 781 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 782 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 783 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 784 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 785 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 786 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 787 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 788 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 789 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 799 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 800 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 801 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 802 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 803 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 804 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 805 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 806 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 807 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 808 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 809 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 810 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 811 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 812 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 813 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 814 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 815 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 816 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 817 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 818 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 819 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 820 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 821 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 822 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 823 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 828 Electronic Brake Control Module: Specifications Control Module Bolts 9 - 17 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 829 View 151-14 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 830 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 831 Electronic Brake Control Module: Service and Repair Module - Anti-Lock Brake Control Removal and Installation 1. Disconnect the battery negative cable. 2. Remove the air cleaner and the air cleaner outlet pipe. 3. Disconnect the electrical connectors. 4. Remove the bolts. 5. Remove the bolt. 6. Raise and support the vehicle. 7. Remove the screws and the control module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 832 8. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay Radiator Cooling Fan Motor Relay: Locations Cooling Fan Low Relay Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 838 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 839 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 840 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 841 Radiator Cooling Fan Motor Relay: Locations High Speed Fan Control Relay 1 Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 842 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 843 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 844 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 845 Radiator Cooling Fan Motor Relay: Locations High Speed Fan Control Relay 2 Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 846 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 847 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 848 Radiator Cooling Fan Motor Relay: Locations Medium Speed Fan Control Relay View 151-12 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 849 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 852 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 853 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 854 Radiator Cooling Fan Motor Relay: Diagrams Medium Speed Fan Control Relay Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 855 Radiator Cooling Fan Motor Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 856 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations View 151-18 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 861 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 862 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 863 Blower Motor Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 864 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 868 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 869 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 870 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 871 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 872 Compressor Clutch Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 873 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Relay > Component Information > Locations View 151-38 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Relay > Component Information > Locations > Page 878 Accessory Relay (Audio, Instrument Cluster, GEM, & Mirrors) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Relay > Component Information > Locations > Page 879 Instrument Panel Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Relay > Component Information > Locations > Page 880 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 885 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 886 Daytime Running Lamp Control Unit: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations View 151-23 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 890 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 891 Daytime Running Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 892 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 896 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 897 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 898 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 899 Fog/Driving Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 900 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 907 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 908 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 909 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 910 Headlamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 911 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 915 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 916 View 151-39 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 917 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 918 Horn Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 919 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 926 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 927 View 151-39 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 928 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 929 Parking Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 930 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 935 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 939 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations View 151-38 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 943 Accessory Relay (Audio, Instrument Cluster, GEM, & Mirrors) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 944 Power Distribution Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 945 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 950 Relay Box: Locations Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 951 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 952 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 955 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 956 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 957 Relay Box: Diagrams Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 958 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 961 Relay Box: Application and ID Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 962 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 963 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Powertrain 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 970 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 971 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 972 View 151-11 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 973 Powertrain Control Module: Diagrams Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 974 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 975 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 976 Powertrain Control Module: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 980 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 981 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 982 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 983 Powertrain Control Module Power Relay: Testing and Inspection Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 984 Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation Solid State Relay Solid State Relay The solid state relay (Figure 124) 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). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation Fuel Pump Driver Module Applications Fuel Pump Driver Module Duty Cycle Signals The Fuel Pump Driver Module (FPDM) communicates diagnostic information to the powertrain control module (PCM) through the Fuel Pump Monitor (FPM) circuit. This information is sent by the FPDM as a duty cycle signal. The three duty cycle signals that may be sent are listed in the table. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Fuel Pump Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 996 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 997 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 998 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 999 Fuel Pump Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1000 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1004 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1005 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1006 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1007 Powertrain Control Module Power Relay: Testing and Inspection Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1008 Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations > Page 1013 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations > Page 1014 View 151-39 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations > Page 1015 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations > Page 1016 Ignition Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations > Page 1017 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations View 151-25 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1022 Air Bag Control Module: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 1025 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 1026 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 1027 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1030 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1031 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1032 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1033 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1034 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1035 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1036 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1037 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1038 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1039 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1040 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1041 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1042 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1043 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1044 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1045 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1046 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1047 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1048 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1049 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1050 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1051 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1052 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Page 1053 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1058 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1059 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1060 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1061 Starter Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1062 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations View 151-17 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 1068 Shift Interlock Relay: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 1069 Shift Interlock Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 1070 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations View 151-29 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 1075 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 1076 Four Wheel Drive Selector Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 1077 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1082 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1083 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1084 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1085 Heated Glass Element Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1086 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1105 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side Power Door Lock Switch: Testing and Inspection Driver Side Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 1108 Door Lock Switch, Driver Side Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 1109 Power Door Lock Switch: Testing and Inspection Passenger Side Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 1110 Door Lock Switch, Passenger Side Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 1114 Power Mirror Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 1115 Exterior Rear View Mirror Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 1116 Exterior Rear View Mirror Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 1120 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. ^ 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 AFTERWARD. ^ 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 1121 Power Seat Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 1122 Seat Adjust Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 1123 Power Seat Switch: Service and Repair 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 AFTERWARD. ^ 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. 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 air bag system is being repaired the air bag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 1124 2. Remove the seat control switch knob. 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. 4. Remove the seat control switch. 1 Remove the screws. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 1128 Power Trunk / Liftgate Lock Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 1129 Liftgate Door Lock Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Roof Opening Panel Position Switch > Page 1134 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Page 1142 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1147 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1148 Wheel Speed Sensor: Specifications Front Anti-Lock Brake Sensor Bolt (4X2) 71 - 89 inch lbs. Front Anti-Lock Brake Sensor Bolt (4X4) 71 - 89 inch lbs. Front Anti-Lock Brake Sensor Wire Retaining Bolt (4X4) 62 - 80 inch lbs. Rear Anti-Lock Brake Sensor Bolt 80 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 1151 View 151-15 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 1152 View 151-27 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 1153 View 151-28 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 1156 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 1157 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 1158 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, Front 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 1161 6. NOTE: Clean off any dirt that may have collected around the sensor before removal. Remove the bolt and the sensor. 7. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 1162 Wheel Speed Sensor: Service and Repair Sensor, Rear Sensor - Rear 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 bolt. 5. Remove the bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 1163 6. NOTE: Clean off any dirt that may have collected around the sensor before removal. Remove the bolt and the sensor. 7. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 1164 Wheel Speed Sensor: Service and Repair Sensor Ring, Front Sensor Indicator - Front Removal and Installation 1. The front anti-lock brake sensor indicator is attached to the halfshaft. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 1165 Wheel Speed Sensor: Service and Repair Sensor Ring, Rear Sensor Indicator - Rear Removal and Installation 1. The rear anti-lock brake sensor indicator is attached to the halfshaft. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1175 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1181 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Page 1182 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1187 Coolant Temperature Sensor/Switch (For Computer): Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1188 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1189 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Partially drain the cooling system. 2. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the electrical connector. 2 Unclip and remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Diagrams > Page 1193 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. See: Powertrain Management/Description and Operation/Powertrain Control Software Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 1199 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 1200 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 1201 Brake Switch (Cruise Control): Description and Operation Brake Pressure Applied Brake Deactivator Switch The Brake Pressure Applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, witch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 1202 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service Precautions > Page 1206 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service Precautions > Page 1207 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Page 1212 Oil Pressure Sender: Service and Repair Oil Pressure Sender Removal and Installation 1. Raise and support the vehicle. 2. Remove the right side splash shield. 3. NOTE: The A/C compressor has been removed for clarity. Remove the oil pressure sender. 1 Disconnect the electrical connector. 2 Remove the sender. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation Evaporator Temperature Sensor/Clutch Cycling Switch: Description and Operation Air Conditioning Evaporator Temperature Sensor A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 1 A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 2 The Air Conditioning Evaporative Temperature (ACET) sensor senses evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance affects the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improving defrost/demist performance, reduce A/C clutch cycling, etc. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1224 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 1225 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1228 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Page 1239 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Transmission Range Sensor Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Transmission Range Sensor > Page 1246 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Brake Pedal Position Switch Brake Pedal Position Switch: Description and Operation Brake Pedal Position Switch Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Brake Pedal Position Switch > Page 1252 Brake Pedal Position Switch: Description and Operation Brake Pressure Applied Brake Deactivator Switch Brake Pressure Applied Brake Deactivator Switch The Brake Pressure Applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, witch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Page 1253 Brake Pedal Position Switch: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 1260 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 1261 Fog/Driving Lamp Switch: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1265 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 rearward 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection Headlamp Dimmer Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 1269 Dimmer Switch, Interior Lamps Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1273 Main Light Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1274 Headlamp Switch, Exterior Lamps Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the upper steering column shroud. 3. Remove the lower steering column shroud. 1. Remove the screws. 2. Remove the lower steering column shroud. 4. Remove the multifunction switch. 1. Disconnect the electrical connector. 2. Remove the screws. 3. Remove the multifunction switch. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation Thermal Manifold Absolute Pressure Sensor Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 40) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1286 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1287 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1288 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1289 Mass Air Flow 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1293 Camshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 1296 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 1297 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation Clutch Pedal Position Switch Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation > Page 1301 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1305 Coolant Temperature Sensor/Switch (For Computer): Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1306 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1307 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Partially drain the cooling system. 2. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the electrical connector. 2 Unclip and remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1311 Crankshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor 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 powertrain control module (PCM). The trigger 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 trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 25). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 1314 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 1315 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the bolts and the right front lower splash shield. 3. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams > Page 1319 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. See: Powertrain Management/Description and Operation/Powertrain Control Software Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1323 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline fuel tank pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1324 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1325 ^ Carry out a leak test. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/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/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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors (Figure 33) and integrated Mass Air Flow (MAF) type (Figure 36), are thermistor devices in which resistance changes with temperature The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged vehicles use (2) IAT sensors. Both sensors are thermistor type devices and operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Currently two types of IAT2 sensors are used. A screw in type (Figure 33) and an integrated type, witch is part of the Thermal Manifold Absolute Pressure (TMAP) sensor (Figure 40). The TMAP sensor consists of a IAT thermistor and a Manifold Absolute Pressure (MAP) sensor. The thermistor portion of the TMAP is used for IAT2 function and operates in the same manner as a non-integrated IAT2. For additional information on the MAP portion of the TMAP, refer to the Thermal Manifold Absolute Pressure Sensor description and operation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1332 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1333 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1334 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the bolt and the KS. NOTE: The KS is located on the RH side of the cylinder block INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature Engine Oil Temperature (EOT) Sensor The Engine Oil Temperature (EOT) sensor (Figure 29) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the engine coolant temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1343 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1344 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1345 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1346 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1347 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1348 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1349 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1350 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1351 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1352 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1353 Heated 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1354 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1355 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1356 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1357 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1358 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1359 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1360 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1361 Heated Oxygen Sensor: Connector Views Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1362 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 1363 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input Heated Oxygen Sensor: Description and Operation PCM Input Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 32) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input > Page 1366 Heated Oxygen Sensor: Description and Operation Upstream Heated and Downstream Heated Oxygen Sensors Upstream Heated and Downstream Heated Oxygen Sensors 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.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH Heated Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) LH EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Raise and support the vehicle. 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH > Page 1369 Heated Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) RH EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 2. Raise and support the vehicle. 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH > Page 1370 Heated Oxygen Sensor: Service and Repair Catalyst Monitor Sensor LH EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Raise and support the vehicle. 2. Disconnect the catalyst monitor sensor electrical connector. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH > Page 1371 Heated Oxygen Sensor: Service and Repair Catalyst Monitor Sensor RH 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Power Steering Pressure Switch: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Page 1375 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Power Steering Pressure (PSP) Switch The Power Steering Pressure (PSP) switch (Figure 37) monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Page 1376 Power Steering Pressure Switch: Service and Repair REMOVAL 1. Remove the Power Steering Pressure (PSP) switch. 1 Disconnect the electrical connector. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1385 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1386 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1387 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1388 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1389 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1395 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1396 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1397 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1398 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1399 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1404 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1405 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1406 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1412 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1413 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1414 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Page 1415 View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Page 1416 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Page 1417 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) 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 aluminum 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Page 1418 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Page 1419 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 151-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1423 Throttle Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1424 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1425 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the nuts and the engine appearance cover. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the sensor NOTE: Air cleaner outlet tube is removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Torque Specifications Transmission range (TR) sensor bolts ................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1429 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1430 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1431 Digital Transmission Range 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1432 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1433 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1434 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input Vehicle Speed Sensor: Description and Operation PCM Input Vehicle Speed Sensor Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 44) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input > Page 1440 Vehicle Speed Sensor: Description and Operation PCM Output Powertrain Control Module - Vehicle Speed Output (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH ( 1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1450 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1451 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1452 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1453 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1454 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1460 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1461 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1462 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1463 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1464 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1469 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1470 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1471 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 1477 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 1478 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 1479 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1480 View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1481 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1482 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) 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 aluminum 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1483 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1484 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1489 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1490 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1491 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1492 Mass Air Flow 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1496 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1497 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 30) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor 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. Fuel Rail Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 31) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor Engine Fuel Temperature (EFT) Sensor The Engine Fuel Temperature (EFT) sensor (Figure 28) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EFT sensor measures the temperature 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1504 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1505 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1506 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 151-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1510 Throttle Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1511 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1512 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the nuts and the engine appearance cover. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the sensor NOTE: Air cleaner outlet tube is removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1517 Camshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 1520 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 1521 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1525 Crankshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor 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 powertrain control module (PCM). The trigger 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 trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 25). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 1528 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 1529 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the bolts and the right front lower splash shield. 3. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the upper steering column shroud. 3. Remove the screws and the lower steering column shroud. 4. Turn the ignition key to the ON position. 5. Using a small tool, depress the ignition lock cylinder release button and pull the ignition lock cylinder out. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1537 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1538 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1539 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the bolt and the KS. NOTE: The KS is located on the RH side of the cylinder block INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Air Bag Sensor, Left > Page 1545 View 151-26 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Air Bag Sensor, Left Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Air Bag Sensor, Left > Page 1548 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 1551 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Page 1552 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1555 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1556 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1557 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1558 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1559 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1560 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1561 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1562 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1563 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1564 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1565 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1566 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1567 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1568 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1569 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1570 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1571 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1572 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1573 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1574 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1575 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1576 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Page 1577 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Page 1594 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Clutch Switch: Locations The Clutch Switch is located near the left hand rocker panel. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch > Page 1601 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the upper steering column shroud. 3. Remove the screws and the lower steering column shroud. 4. Turn the ignition key to the ON position. 5. Using a small tool, depress the ignition lock cylinder release button and pull the ignition lock cylinder out. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Digital Transmission Range Sensor <--> [Neutral Safety Switch] > Component Information > Locations View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Digital Transmission Range Sensor <--> [Neutral Safety Switch] > Component Information > Locations > Page 1609 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams Power Steering Pressure Switch: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Page 1615 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Power Steering Pressure (PSP) Switch The Power Steering Pressure (PSP) switch (Figure 37) monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Page 1616 Power Steering Pressure Switch: Service and Repair REMOVAL 1. Remove the Power Steering Pressure (PSP) switch. 1 Disconnect the electrical connector. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs Transmission Mode Switch: Description and Operation PCM Inputs TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs > Page 1623 Transmission Mode Switch: Description and Operation PCM Output Transmission Control Indicator Lamp The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch in Hardware PCM Inputs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Torque Specifications Transmission range (TR) sensor bolts ................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1627 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1628 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1629 Digital Transmission Range 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1630 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1631 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1632 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Transmission Speed Sensor: Customer Interest A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Article No. 02-2-4 02/04/02 TRANSAXLE - CD4E - HARSH AND DELAYED 1-2/2-3 UPSHIFTS - AFTER TRANSAXLE OR TURBINE SHAFT SPEED SENSOR (TSS) REPLACEMENT - POSSIBLE DIAGNOSTIC TROUBLE CODES (DTC) 628, 642, 645, 646, 647, 648, P0731, P0732, P0734, P0741, AND P1744 FORD: 1994-1997 PROBE 1995-2000 CONTOUR 2001-2002 ESCAPE MERCURY: 1995-2000 MYSTIQUE 1999-2002 COUGAR ISSUE Some vehicles equipped with the CD4E transaxle may exhibit harsh and delayed 1-2/2-3 upshifts along with DTCs for gear ratio errors after the Transaxle or Turbine Shaft Speed sensor (TSS) have been replaced. DTCs may include OBD1 codes 628, 642, 645, 646, 647, 648, or OBD II codes P0731, P0732, P0734, P0741, and P1744 ACTION If the condition occurred after servicing the Transaxle or TSS, refer to the following TSS Selection Chart and select the correct TSS for the vehicle application. Note that each TSS has the Ford engineering part number on it. Also note that there is a TSS kit that includes an instruction sheet, TSS sensor and correct bolt. SERVICE PROCEDURE Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored > Page 1641 If the condition occurred after replacing the Transaxle or TSS, use the TSS Selection Chart and determine the correct sensor for the vehicle. 1. Remove the existing TSS from the CD4E pump body. 2. Reinstall the original TSS sensor, if available, or install the correct TSS as indicated in the Selection Chart. 3. Clear all codes and verify repair. 4. If the condition still exists, follow normal diagnostics as listed in the appropriate model year Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Transmission Speed Sensor: All Technical Service Bulletins A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Article No. 02-2-4 02/04/02 TRANSAXLE - CD4E - HARSH AND DELAYED 1-2/2-3 UPSHIFTS - AFTER TRANSAXLE OR TURBINE SHAFT SPEED SENSOR (TSS) REPLACEMENT - POSSIBLE DIAGNOSTIC TROUBLE CODES (DTC) 628, 642, 645, 646, 647, 648, P0731, P0732, P0734, P0741, AND P1744 FORD: 1994-1997 PROBE 1995-2000 CONTOUR 2001-2002 ESCAPE MERCURY: 1995-2000 MYSTIQUE 1999-2002 COUGAR ISSUE Some vehicles equipped with the CD4E transaxle may exhibit harsh and delayed 1-2/2-3 upshifts along with DTCs for gear ratio errors after the Transaxle or Turbine Shaft Speed sensor (TSS) have been replaced. DTCs may include OBD1 codes 628, 642, 645, 646, 647, 648, or OBD II codes P0731, P0732, P0734, P0741, and P1744 ACTION If the condition occurred after servicing the Transaxle or TSS, refer to the following TSS Selection Chart and select the correct TSS for the vehicle application. Note that each TSS has the Ford engineering part number on it. Also note that there is a TSS kit that includes an instruction sheet, TSS sensor and correct bolt. SERVICE PROCEDURE Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored > Page 1647 If the condition occurred after replacing the Transaxle or TSS, use the TSS Selection Chart and determine the correct sensor for the vehicle. 1. Remove the existing TSS from the CD4E pump body. 2. Reinstall the original TSS sensor, if available, or install the correct TSS as indicated in the Selection Chart. 3. Clear all codes and verify repair. 4. If the condition still exists, follow normal diagnostics as listed in the appropriate model year Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 1648 Transmission Speed Sensor: Specifications Torque 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1651 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Page 1654 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Page 1655 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 sea] as necessary. Installation NOTE: Apply a light coat of petroleum jelly to the O-ring before installation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1658 1. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1659 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Material Materials 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1660 6. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Torque Specifications Vehicle speed sensor (VSS) bolt ........................................................................................................................................................ 7 Nm (62 inch lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Output Shaft Speed Sensor View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Output Shaft Speed Sensor > Page 1667 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page 1670 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 1671 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 1672 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS)-4x4 Removal and Installation 1. Disconnect the vehicle speed sensor (VSS) electrical connector. 2. Raise the vehicle on the hoist. 3. Remove the bolt and the VSS. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 1677 Four Wheel Drive Selector Switch: Description and Operation 4x4 MODE SWITCH Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 2WD (Figure 46). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 1678 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Remove the mode select switch (MSS) knob. 2. Remove the instrument panel center finish panel. 3. Remove the MSS. 1. Remove the screws. 2. Remove the MSS. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 1683 Heated Glass Element Switch: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1688 Power Window Switch: Diagrams Window Adjust Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1689 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1692 Master Window Control Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1693 Master Window Control Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1694 Power Window Switch: Testing and Inspection Window Adjust Switch Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1695 Window Adjust Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 1696 Power Window Switch: Service and Repair REMOVAL NOTE: The removal and installation procedures for all window control switches are similar. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1701 Windshield Washer Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1702 Wiper/washer Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1703 Windshield Washer Switch: Service and Repair REMOVAL 1. Remove the steering column shroud. NOTE: The windshield wiper/washer switch is part of the multifunction switch assembly. 2. Remove the screws. 3. Remove the windshield wiper/washer switch. 1 Disconnect the electrical connector. 2 Remove the windshield wiper/washer switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1707 Wiper Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1708 Wiper/washer Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1709 Wiper Switch: Service and Repair REMOVAL 1. Remove the steering column shroud. NOTE: The windshield wiper/washer switch is part of the multifunction switch assembly. 2. Remove the screws. 3. Remove the windshield wiper/washer switch. 1 Disconnect the electrical connector. 2 Remove the windshield wiper/washer switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > By Symptom: > 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > By Symptom: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 1719 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > By Symptom: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 1720 3. Complete worksheet as needed (Figure 5). GENERAL FRONT SUSPENSION UPPER STRUT MOUNT ADJUSTMENT INFORMATION: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > By Symptom: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 1721 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > By Symptom: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 1722 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 1728 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 1729 3. Complete worksheet as needed (Figure 5). GENERAL FRONT SUSPENSION UPPER STRUT MOUNT ADJUSTMENT INFORMATION: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 1730 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 1731 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 06-3-5 > Feb > 06 > Engine - Left Bank Cylinder Head Ticking Noise Camshaft Bearing: All Technical Service Bulletins Engine - Left Bank Cylinder Head Ticking Noise TSB 06-3-5 02/20/06 CAMSHAFT TICK NOISE - 3.0L 4V ENGINE ONLY FORD: 2001-2005 Taurus 2001-2006 Escape MERCURY: 2001-2005 Sable 2005-2006 Mariner This article supersedes TSB 04-20-8 to update the vehicle model years and Service Procedure. ISSUE Some 2001-2005 Taurus/Sable, 2001-2006 Escape and 2005-2006 Mariner vehicles built prior to 1-17-2006 equipped with the 3.0L 4V Duratec engine may exhibit a ticking noise from the left bank cylinder head, with the engine at normal operating temperature only. ACTION To diagnose, with the engine running and warm (normal operation temperature), using a mechanic's stethoscope determine if the ticking noise is coming from the left hand intake camshaft at cylinder number 6, (Figure 1). If the ticking noise can be verified, refer to the following Service Procedure. SERVICE PROCEDURE 1. Remove the left bank valve cover. Refer to Workshop Manual, Section 303-01B. 2. Rotate the engine clock wise until the cylinder number 6 intake cam lobes are pointing up and the valves are fully closed. 3. Remove all left hand intake cam caps individually and reinstall them finger tight. NOTE THE CAMSHAFT CAPS MUST BE COMPLETELY LIFTED OFF AND THEN SET BACK INTO POSITION. LOOSENING AND RE-TORQUEING CAP BOLTS IS NOT SUFFICIENT. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 06-3-5 > Feb > 06 > Engine - Left Bank Cylinder Head Ticking Noise > Page 1737 4. Torque bolts in sequence shown in Figure 2 to 72 lb-in (8 N.m) excluding cam cap number 8L camshaft cap. 5. Using a screw driver positioned on each side of the top of cam cap number 8L (Figure 3) apply hand pressure and shift cam cap number 8L toward the exhaust side of the cylinder head. 6. While holding cam cap number 8L in the shifted position, torque the fasteners number 9 (inboard) first, to 72 lb-in (8 N.m) then torque fastener number 10 (Figure 3). 7. Install the left hand camshaft cover. Refer to appropriate Workshop Manual, Section 303-01. 8. Fully warm the engine to normal operating temperature to verify the repair. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 060305A 2001-2003 Taurus/Sable: 0.9 Hr. Remove And Install The Camshaft Caps Includes Time To Remove And Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 06-3-5 > Feb > 06 > Engine - Left Bank Cylinder Head Ticking Noise > Page 1738 Install Valve Cover (Do Not Use With 6007A10, 6250AL, 6584AL) 060305A 2004-2005 1.0 Hr. Taurus/Sable: Remove And Install The Camshaft Caps Includes Time To Remove And Install Valve Cover (Do Not Use With 6007A10, 6250AL, 6584AL) 060305A 2001-2006 Escape and 1.2 Hrs. 2005-2006 Mariner: Remove And Install The Camshaft Caps Includes Time To Remove And Install Valve Cover (Do Not Use With 6007A10, 6250AL, 6584AL) DEALER CODING CONDITION BASIC PART NO. CODE 6A267 07 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 06-3-5 > Feb > 06 > Engine - Left Bank Cylinder Head Ticking Noise > Page 1744 4. Torque bolts in sequence shown in Figure 2 to 72 lb-in (8 N.m) excluding cam cap number 8L camshaft cap. 5. Using a screw driver positioned on each side of the top of cam cap number 8L (Figure 3) apply hand pressure and shift cam cap number 8L toward the exhaust side of the cylinder head. 6. While holding cam cap number 8L in the shifted position, torque the fasteners number 9 (inboard) first, to 72 lb-in (8 N.m) then torque fastener number 10 (Figure 3). 7. Install the left hand camshaft cover. Refer to appropriate Workshop Manual, Section 303-01. 8. Fully warm the engine to normal operating temperature to verify the repair. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 060305A 2001-2003 Taurus/Sable: 0.9 Hr. Remove And Install The Camshaft Caps Includes Time To Remove And Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 06-3-5 > Feb > 06 > Engine - Left Bank Cylinder Head Ticking Noise > Page 1745 Install Valve Cover (Do Not Use With 6007A10, 6250AL, 6584AL) 060305A 2004-2005 1.0 Hr. Taurus/Sable: Remove And Install The Camshaft Caps Includes Time To Remove And Install Valve Cover (Do Not Use With 6007A10, 6250AL, 6584AL) 060305A 2001-2006 Escape and 1.2 Hrs. 2005-2006 Mariner: Remove And Install The Camshaft Caps Includes Time To Remove And Install Valve Cover (Do Not Use With 6007A10, 6250AL, 6584AL) DEALER CODING CONDITION BASIC PART NO. CODE 6A267 07 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1746 Alignment: Specifications Front Alignment Specifications Rear Alignment Specifications Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1749 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1750 7. Tighten the nuts. 8. Install the clamp(s). 9. Recheck the toe settings. Follow the equipment manufacturer's instructions. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1751 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1752 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions Fuel Pressure Test Port: 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. ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 1758 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 1759 Fuel Pressure Test Port: 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 pressure. 2. Remove the pressure relief valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 730 - 750 RPM Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1771 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) 1. Remove the Schrader valve cap at the end of the fuel injection supply manifold and attach the Fuel Pressure Gauge. 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. Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. NOTE: Position a suitable container for the fuel to drain into. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1772 Fuel Pressure Gauge Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications V6 Firing Order: 1 4 2 5 3 6 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 1776 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark plug gap..................................................................................................................................... ................................1.3 - 1.4 mm (0.052 - 0.056 inch) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 1788 Spark Plug: Specifications Torque Spark plugs........................................................................................................................................... ........................................................15 Nm (11 Lb-Ft) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1789 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1790 Spark Plug: Application and ID Spark plug............................................................................................................................................ ...................................................................AWSF-32F Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1791 Spark Plug: Service and Repair REMOVAL 1. Remove the ignition coil-on-plugs. 2. Remove the LH and RH spark plugs. NOTE: LH shown, RH similar. 3. Inspect the spark plugs. INSTALLATION 1. To install, the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1795 Compression Check: Testing and Inspection Compression Test General Remarks NOTE: Removing fuses and disconnecting electrical components causes the Powertrain Control Module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. NOTE: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check the Compression Pressure. WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, 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. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other are both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Accessory Drive 2.0L Zetec without A/C 2.0L Zetec with A/C Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1799 3.0L (4V) with A/C Water Pump Drive Belt-3.0L (4V) with Tensioner Water Pump Drive Belt-3.0L (4V) without Tensioner Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 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 following 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 Crack 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1802 Drive Belt: Symptom Related Diagnostic Procedures Symptom Chart Part 1 of 2 Part 2 of 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1803 Drive Belt: Component Tests and General Diagnostics Belt Tensioner-Dynamic 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. Belt Tensioner-Mechanical 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Drive Belt: Service and Repair Drive Belt Accessory Drive Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt > Page 1806 Drive Belt: Service and Repair Water Pump With Tensioner Water Pump Belt-3.0L (4V) with Tensioner Removal and Installation 1. Remove the nuts and the engine appearance cover. 2. Rotate the drive belt tensioner clockwise and remove the water pump belt. 3. To install, reverse the removal procedure. Without Tensioner Water Pump Belt-3.0L (4V) without Tensioner Removal 1. Remove the nuts and the engine appearance cover. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt > Page 1807 2. Rotate the crankshaft clockwise and remove the water pump belt by walking off the pulley. Installation 1. Partially start the water pump belt on the pulley. 2. Rotate the crankshaft clockwise and install the water pump belt by walking on the pulley. 3. Install the engine appearance cover and the nuts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service Precautions > Page 1819 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service Precautions > Page 1820 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/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/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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Locations > Page 1824 Special Tool Seal Removal Transmission Filter Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1829 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) 1. Remove the Schrader valve cap at the end of the fuel injection supply manifold and attach the Fuel Pressure Gauge. 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. Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. NOTE: Position a suitable container for the fuel to drain into. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1830 Fuel Pressure Gauge Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair Bypass Tube-3.0L (4V) Removal and Installation 1. Drain the engine Cooling System. 2. Remove the air cleaner outlet tube. 3. Disconnect the five hoses from the thermostat housing and remove the thermostat housing. 4. Disconnect the Engine Coolant Temperature (ECT) sensor from the bypass tube. 5. Remove the bolt, stud, and the water bypass tube. 6. NOTE: Clean and inspect the sealing surfaces. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1843 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1844 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1850 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1851 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1852 Heater Hose: Service and Repair REMOVAL 1. Drain the engine coolant. 2. Disconnect the heater hoses from the heater core. 3. Disconnect the heater outlet hose from the water hose connection. 4. Disconnect the heater hose connection from the engine. 5. Remove the heater hose from the engine compartment. 6. Disconnect the heater hoses from the heater hose junction. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions > Page 1856 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions > Page 1857 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 02-5-2 > Mar > 02 > Power Steering - Leaks in Extreme Cold Power Steering Line/Hose: Customer Interest Power Steering - Leaks in Extreme Cold Article No. 02-5-2 03/01/02 STEERING - POWER STEERING FLUID LEAK DURING EXTREME COLD AMBIENT TEMPERATURES -20 TO -28C (-5 TO -20F) - VEHICLES PRODUCED 2/12/2002 ONLY FORD: 2001-2002 ESCAPE ISSUE Some vehicles built before 2/12/2002 may exhibit a power steering fluid leak at the Return Hose and/or Cooler Hose at the Intermediate Tube Assembly during extreme cold ambient temperatures -20 to -28°C (-5 to -20 °F). This may be caused by hose blow out due to an increase in fluid viscosity during extreme cold temperatures. ACTION Replace the Intermediate Tube with a steel intermediate tube and replace spring type clamps on Return Hose and Cooler Hose with worm type clamps to increase hose retention. SERVICE PROCEDURE 1. Perform procedure in Workshop Manual Section 211-02 to remove Return Hose and Cooler Hose from Intermediate Tube. 2. Replace Intermediate Tube with new part 2L8Z-3A713-AA. 3. Reinstall Cooler and Return Hoses using worm clamps 376240-S100. 4. Bleed all of the air from steering system using bleed procedure in Section 211-00 of the appropriate year Workshop Manual. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020502A Replace Metal Section Of 1.0 Hr. Power Steering Return Hose (Includes Time To Bleed Air From System) DEALER CODING CONDITION BASIC PART NO. CODE 3A713 42 OASIS CODES: 303000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 02-5-2 > Mar > 02 > Power Steering Leaks in Extreme Cold Power Steering Line/Hose: All Technical Service Bulletins Power Steering - Leaks in Extreme Cold Article No. 02-5-2 03/01/02 STEERING - POWER STEERING FLUID LEAK DURING EXTREME COLD AMBIENT TEMPERATURES -20 TO -28C (-5 TO -20F) - VEHICLES PRODUCED 2/12/2002 ONLY FORD: 2001-2002 ESCAPE ISSUE Some vehicles built before 2/12/2002 may exhibit a power steering fluid leak at the Return Hose and/or Cooler Hose at the Intermediate Tube Assembly during extreme cold ambient temperatures -20 to -28°C (-5 to -20 °F). This may be caused by hose blow out due to an increase in fluid viscosity during extreme cold temperatures. ACTION Replace the Intermediate Tube with a steel intermediate tube and replace spring type clamps on Return Hose and Cooler Hose with worm type clamps to increase hose retention. SERVICE PROCEDURE 1. Perform procedure in Workshop Manual Section 211-02 to remove Return Hose and Cooler Hose from Intermediate Tube. 2. Replace Intermediate Tube with new part 2L8Z-3A713-AA. 3. Reinstall Cooler and Return Hoses using worm clamps 376240-S100. 4. Bleed all of the air from steering system using bleed procedure in Section 211-00 of the appropriate year Workshop Manual. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020502A Replace Metal Section Of 1.0 Hr. Power Steering Return Hose (Includes Time To Bleed Air From System) DEALER CODING CONDITION BASIC PART NO. CODE 3A713 42 OASIS CODES: 303000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 1871 Power Steering Line/Hose: Specifications Power steering pressure line bracket-to-engine insulator bracket bolt, 3.0L (4V) 89 inch lbs. Power steering pressure hose to steering gear fitting 21-25 ft. lbs. Power steering pressure line-to-pump fitting 48 ft. lbs. Power steering pressure and return line retainer plate-to-gear bolt 18 ft. lbs. Power steering pressure line bracket-to-gear bolt 89 inch lbs. Power steering return line bracket-to-gear bolt 89 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Fluid High Performance DOT 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Service Precautions > Customer Safety Information Brake Fluid: Customer Safety Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Service Precautions > Customer Safety Information > Page 1878 Brake Fluid: Technician Safety Information 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. . Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Service Precautions > Customer Safety Information > Page 1879 Brake Fluid: Vehicle Damage Warnings 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info > Page 1884 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info > Page 1885 Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info > Page 1886 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling system refill capacities (3.0L 4V) 10.5 quart Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1889 Coolant: Fluid Type Specifications Type Motorcraft Premium Engine Coolant Caution: Do not mix coolant types. Motorcraft Premium Gold Engine Coolant Motorcraft Premium Cooling System Flush Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications Differential Fluid - A/T: Capacity Specifications Fluid Capacity 2.0L (Oil Cooler) .................................................................................................................................. .................................................................. 9.0 qts 3.0L (Oil Cooler) ................................................... ............................................................................................................................................... 10.2 qts Differential fluid capacity is fill as necessary with Mercon ATF. Differential is combined in Transmission housing for 4WD. Note: 3.0L 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1894 Differential 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Differential Fluid - Transfer Case: Capacity Specifications Manual Transmission Capacity SAE 75W90 ......................................................................................................................................... ..................................................... 2.2L (2.32 qts.) Note: Fluid level must be even with the bottom of the filler hole. Manual Transmission and Differential are combined in same housing for 4WD. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1899 Differential Fluid - Transfer Case: Fluid Type Specifications SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B Ford Specification ................................................................................................................................ ....................................................... WSL-M2C192-A Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering Fluid - A/T: Customer Interest Engine Controls/A/T - Unstable Idle/Shuddering TSB 06-11-7 06/12/06 2001-2005 ESCAPE 3.0L UNSTABLE IDLE - 2001-2003 ESCAPE 3.0L AUTOMATIC TRANSAXLE SHUDDER - MEXICO ONLY FORD: 2001-2005 Escape ISSUE Some 2001-2005 Escape vehicles equipped with a 3.0L engine may exhibit idle speeds outside the specified range. Some 2001-2003 Escape vehicles equipped with a 3.0L engine and CD4E automatic transaxle may exhibit a transmission shudder. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. If the concern is a 2001-2005 Escape with idle speeds outside the specified range: a. Install a new idle air control (IAC) valve with jumper harness included in the kit. The new Denso brand IAC will be installed with the electrical connector facing the opposite direction of the original (Hitachi) valve which is why the jumper harness is required. The original (Hitachi) IAC connector faces the front of the vehicle while the new Denso IAC connector faces toward the rear of the vehicle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 1908 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 1909 b. Referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the powertrain control module (PCM) using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 2. If the concern is a 2001 - 2003 Escape with transaxle shudder, drain, flush and refill the transmission fluid with MERCON(R) Multi-Purpose Automatic Transmission Fluid. Then, referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the PCM using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 3. When reprogramming the PCM use blank path programming. Select the proper file from the chart and manually enter the PCM part number or tear tag number to obtain the updated calibration file. To Perform Blank Path Programming: 1. Connect WDS/IDS to vehicle. 2. Select "16 pin", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 5. 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. 6. Screen shows to turn ignition ON. Keep ignition in the "OFF" position, press TICK and you will be asked to cycle the key "ON" and "OFF" a few times. Please keep the key position in the "OFF" position through the key cycles. 7. Screen will show "The diagnostic tester is unable to communicate with this vehicle." You will be prompted to "select a vehicle from the vehicle list", press TICK. 8. A list of vehicles will be displayed, select ALL OTHERS, and press TICK. 9. Screen shows "To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration number (7 digits), Tear Tag number (4 digits), or PCM part number, press TICK. 10. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 11. Follow and answer correctly all remaining screens. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) per Workshop Manual, Section 419-01. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 1910 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9F715 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage Fluid - A/T: All 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 1916 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 1917 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering Fluid - A/T: All Technical Service Bulletins Engine Controls/A/T - Unstable Idle/Shuddering TSB 06-11-7 06/12/06 2001-2005 ESCAPE 3.0L UNSTABLE IDLE - 2001-2003 ESCAPE 3.0L AUTOMATIC TRANSAXLE SHUDDER - MEXICO ONLY FORD: 2001-2005 Escape ISSUE Some 2001-2005 Escape vehicles equipped with a 3.0L engine may exhibit idle speeds outside the specified range. Some 2001-2003 Escape vehicles equipped with a 3.0L engine and CD4E automatic transaxle may exhibit a transmission shudder. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. If the concern is a 2001-2005 Escape with idle speeds outside the specified range: a. Install a new idle air control (IAC) valve with jumper harness included in the kit. The new Denso brand IAC will be installed with the electrical connector facing the opposite direction of the original (Hitachi) valve which is why the jumper harness is required. The original (Hitachi) IAC connector faces the front of the vehicle while the new Denso IAC connector faces toward the rear of the vehicle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 1922 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 1923 b. Referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the powertrain control module (PCM) using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 2. If the concern is a 2001 - 2003 Escape with transaxle shudder, drain, flush and refill the transmission fluid with MERCON(R) Multi-Purpose Automatic Transmission Fluid. Then, referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the PCM using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 3. When reprogramming the PCM use blank path programming. Select the proper file from the chart and manually enter the PCM part number or tear tag number to obtain the updated calibration file. To Perform Blank Path Programming: 1. Connect WDS/IDS to vehicle. 2. Select "16 pin", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 5. 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. 6. Screen shows to turn ignition ON. Keep ignition in the "OFF" position, press TICK and you will be asked to cycle the key "ON" and "OFF" a few times. Please keep the key position in the "OFF" position through the key cycles. 7. Screen will show "The diagnostic tester is unable to communicate with this vehicle." You will be prompted to "select a vehicle from the vehicle list", press TICK. 8. A list of vehicles will be displayed, select ALL OTHERS, and press TICK. 9. Screen shows "To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration number (7 digits), Tear Tag number (4 digits), or PCM part number, press TICK. 10. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 11. Follow and answer correctly all remaining screens. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) per Workshop Manual, Section 419-01. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 1924 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9F715 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage Fluid - A/T: All 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 1930 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 1931 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 2.0L (Oil Cooler) ................................................................................................... .............................................................................................. 10 qts 9.5L 3.0L (Oil Cooler) ................ .............................................................................................................................................................. ................... 10 qts 9.5L Service (Oil Change only) .................................................................................................................... ....................................................................... 3.9 qts Note: 3.0L 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1934 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1935 Fluid - A/T: Service and Repair Transmission Fluid Drain And Refill Removal 1. Raise and support the vehicle. 2. Place a suitable container under the transaxle drain plug. 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. 3. 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 (D DBAZ-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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Capacity ............................................................................................................................................... ................................................................. 2.32 Quarts Note: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1940 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid Type ..................................................................................................................................................... ...................................... SAE 75W90 Gear OiL GL4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications With 4-SPD Automatic Differential Oil Capacity 2.0L (Oil Cooler) .................................................................................................................................. ........................................................................ 9.0 qts 3.0L (Oil Cooler) ............................................. ........................................................................................................................................................... 10.2 qts Differential fluid capacity is fill as necessary with Mercon ATF. Differential is combined in Transmission housing for 4WD. Note: 3.0L Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. With 5-SPD Manual Manual Transmission Capacity SAE 75W90 ......................................................................................................................................... ........................................................... 2.2L (2.32 qts.) Note: Fluid level must be even with the bottom of the filler hole. Manual Transmission and Differential are combined in same housing for 4WD. Rear Differential 2WD/4WD Differential Oil Capacity Refill ..................................................................................................................................................... ............................................................. 1.4L (3.0 pts) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1945 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Type ..................................................................................................................................................... ............................... SAE 80W-90 High Performance Ford Part Number ............................................ ............................................................................................................................................. FITZ-19580-B Ford Specification ........................................................................................................ .............................................................................. WSP-M2C197-A Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Mechanical Specifications Fluid - Transfer Case: Mechanical Specifications Torque Specifications Drain plug ............................................................................................................................................ ............................................. 10 Nm (89 inch lbs.) Fill plug ................................................................. ................................................................................................................................ l6 Nm (12 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Mechanical Specifications > Page 1950 Fluid - Transfer Case: Capacity Specifications Auto/Manual Power Take-Off Unit ....................................................................................................... ........................................................................ 12 oz. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Mechanical Specifications > Page 1951 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ................................................................................................................................................ SAE 75W-140 High Performance Rear Axle Lubricant Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1956 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1957 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1958 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 5.2L (5.5 Qt) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1961 Engine Oil: Fluid Type Specifications Engine Oil Type ....................................................................................................................................................... Super Premium SAE 5W-20 Motor Oil Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 1966 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power steering fluid capacity 2.0 quarts Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1969 Power Steering Fluid: Fluid Type Specifications MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Capacity 850 kg (1 lb, 14 oz) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1974 Refrigerant: Fluid Type Specifications Refrigerant Fluid Type Refrigerant Fluid Type R-134a Refrigerant YN-19 WSH-M17B19-A Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Environmental Impact Information Refrigerant: Environmental Impact Information The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Additional Information Sources For more complete and detailed explanations of the above policies, please refer to: http://www.epa.gov/ozone/ Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/ Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Environmental Impact Information > Page 1977 Fax: 215-541-4635 http://www.macsw.org/ Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Environmental Impact Information > Page 1978 Refrigerant: Vehicle Damage Warnings 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Electronic Leak Detection > Page 1981 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Electronic Leak Detection > Page 1982 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Discharging and Recovery > Page 1985 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Discharging and Recovery > Page 1986 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Discharging and Recovery > Page 1987 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 1988 Refrigerant: Tools and Equipment Refrigerent Leak Detector Special Tool(s) Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 1989 Delux A/C Refrigerant Analyzer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Capacity 266 ml (9 oz) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1994 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type Refrigerant Oil Type PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) WSH-M1C231-B Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1995 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1996 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1997 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service Precautions > Technician Safety Information Brake Bleeding: Technician Safety Information 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: 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. 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service Precautions > Technician Safety Information > Page 2002 Brake Bleeding: Vehicle Damage Warnings 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed Brake Bleeding: Service and Repair Brake Master Cylinder - Bench Bleed 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2005 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2006 Brake Bleeding: Service and Repair Brake Master Cylinder - In-Vehicle Bleed 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. 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 4 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2007 Brake Bleeding: Service and Repair Brake System Gravity Bleeding 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2008 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2009 Brake Bleeding: Service and Repair Brake System Manual Bleeding Manual Bleed 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 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. 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2010 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2011 Brake Bleeding: Service and Repair Brake Master Cylinder - Bench Bleed 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2012 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 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. 2. Install short brake hoses to the master cylinder outlet ports with the ends submerged in the brake master cylinder reservoir. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2013 3. Fill the brake master cylinder reservoir with 4 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. Brake System Gravity Bleeding 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2014 4. Tighten the wheel cylinder bleeder screw. 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 Manual Bleeding Manual Bleed 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2015 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. 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. 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2016 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. 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. Brake System Pressure Bleeding 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 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2017 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2018 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. Four Wheel Antilock Brake System Bleeding 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2024 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2025 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2026 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2027 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2028 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2029 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 2035 Fuse: Locations Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 2036 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 2037 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2040 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2041 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2042 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2043 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2044 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2045 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2046 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2047 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2048 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2049 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2050 Fuse: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2051 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2052 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2053 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2054 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2055 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2056 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2057 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 2060 Fuse: Application and ID Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 2061 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 2062 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box Fuse Block: Locations Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box > Page 2067 Fuse Block: Locations Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box > Page 2068 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box > Page 2069 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2072 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2073 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2074 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2075 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2076 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2077 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2078 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2079 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2080 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2081 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2082 Fuse Block: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2083 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2084 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2085 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2086 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2087 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2088 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2089 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2090 Fuse Block: Connector Views Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2091 Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2092 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2093 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2094 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 2097 Fuse Block: Application and ID Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 2098 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 2099 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box > Page 2104 Relay Box: Locations Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box > Page 2105 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box > Page 2106 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Central Junction Box Relay Box: Diagrams Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Central Junction Box > Page 2109 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Central Junction Box > Page 2110 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Central Junction Box > Page 2111 Relay Box: Diagrams Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Central Junction Box > Page 2112 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 2115 Relay Box: Application and ID Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 2116 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 2117 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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) Check Engine, Service Engine Soon Or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control Module (PCM) has detected an On Board Diagnostic (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 16). ^ 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. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Reading Diagnostic Trouble Codes/Performance Diagnostic Procedures/Quick Test ^ 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1. The front jacking point is at the bolt head of the lower control arm. Jacking Points - Rear 1. The rear jacking points are located on the rear trailing arms. LIFTING Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 2129 Lifting Points 1. The lifting points are part of the uni-body structure. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2134 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Wheels: Customer Interest Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Wheels: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 2152 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 2158 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2159 Wheels: Specifications Type Wheel Runout Aluminum Max. Radial Runout 0.06 inch Max. Lateral Runout 0.08 inch Steel Max. Radial Runout 0.06 inch Max. Lateral Runout 0.08 inch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Special Tool(s) Part 1 of 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2165 Part 2 of 2 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2166 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2167 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2168 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. 13. If necessary, remove the brake disc shield. Installation All vehicles 1. If necessary, install a disc brake shield. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2169 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2170 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2171 10. Install the wheel hub nut. 11. Install the brake disc. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2172 Wheel Bearing: Service and Repair Rear Suspension Special Tool(s) Part 1 of 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2173 Part 2 of 3 Part 3 of 3 Removal and Installation All vehicles 1. Remove the brake shoes. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2174 2. Remove the rear halfshaft nut. 3. Using the the special tool, loosen the halfshaft from the wheel hub. 4. Using the special tools, remove the wheel hub. 5. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2175 Vehicles with ABS 6. 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 7. Disconnect the parking brake cable. ^ 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. 10. Remove the lower shock absorber nut. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2176 11. NOTE: It may be necessary to hold the ball joint stud to keep it from turning while removing the nut. Disconnect the lower ball joint. ^ Remove the nut. 12. NOTE: It may be necessary to hold the ball joint stud to keep it from turning while removing the nut. Disconnect the upper ball joint. ^ Remove the nut. 13. NOTE: Note the position of the spring insulator and spring for installation. Remove the spring. ^ Lower the support to the wheel knuckle. 14. Remove the wheel knuckle cam bolt. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2177 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 snap ring. 17. Using the special tools, press the outer wheel bearing race from the wheel knuckle. Installation All vehicles 1. Using the special tools, install a new wheel bearing into the wheel knuckle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2178 2. Install the snap ring into the wheel knuckle. 3. Using the special tools, install the wheel hub. 4. Position the wheel knuckle and install the wheel knuckle cam. ^ Position the halfshaft into the wheel hub. 5. Install the wheel knuckle cam bolt loosely. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2179 6. Support the wheel knuckle and install the spring. 7. Install the lower shock absorber nut. 8. Install the upper ball joint. ^ Install the nut. 9. Install the lower ball joint. ^ Install the nut. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2180 10. Tighten the wheel knuckle cam bolt. 1. Align the wheel knuckle cam. 2. Tighten the wheel knuckle cam bolt. 11. Install the brake line to the wheel cylinder. ^ Install the brake line bracket bolt. 12. Install the parking brake cable onto the backing plate. 1. Install the bolt. 2. Install the parking brake cable onto the backing plate. Vehicles with ABS 13. Position the Anti-Lock (ABS) Brake Sensor and bracket bolts. ^ Install the bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2181 14. Using the special tool, install the halfshaft end into the hub assembly. All vehicles 15. Install the halfshaft nut. 16. Install the brake shoes. 17. Bleed the brake system. 18. Check and adjust the wheel alignment as necessary. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Torque Specifications Front Drive Halfshafts Wheel hub nut ..................................................................................................................................... ........................................ 290 Nm (214 ft. lbs.) Rear Drive Halfshafts Rear axle wheel hub nut .............................................................................................................................................................. 290 Nm (214 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel nuts (all wheels) 98 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Studs Removal and Installation 1. Remove the front wheel bearing. 2. Press out the wheel studs. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 2191 Wheel Fastener: Service and Repair Rear Suspension Wheel Studs Removal and Installation 1. Remove the wheel bearing. 2. Press out the wheel studs. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1. The front jacking point is at the bolt head of the lower control arm. Jacking Points - Rear 1. The rear jacking points are located on the rear trailing arms. LIFTING Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 2195 Lifting Points 1. The lifting points are part of the uni-body structure. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Cam Timing System Variable Valve Timing Solenoid: Description and Operation Variable Cam Timing System Overview The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the combustion chamber. The residual gases cool the combustion chamber and are inert when mixed with the incoming fresh charge of fuel and air. This results in better fuel economy and lower Nitrogen Oxides (NOx) and Hydrocarbons (HC) the engine produces. The Exhaust Gas Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature. Variable Cam Timing Variable Cam Timing System The Variable Cam Timing (VCT) System consists of the control solenoid, five-tooth pulse ring (4+1) on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP) sensor, Powertrain Control Module (PCM) (Figure 127). 1. The powertrain control module (PCM) receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, camshaft position (CMP) sensor, mass air flow (MAF) sensor and crankshaft position (CKP) sensor for determining the operating conditions of the engine. 2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are met. The PCM disables the VCT system if a fault is detected. 3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse ring mounted on the exhaust camshaft. Relative cam position is calculated by measuring the time between the rising edge of Profile Ignition Pickup (PIP) and the falling edge of VCT pulse. 4. The PCM continually calculates a cam position error value based on the difference between the desired and actual position and a duty cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit. 5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a rotation motion from the helical mechanism in the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve to correct for cam position error. Hardware Variable Cam Timing (VCT) Solenoid Valve Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Cam Timing System > Page 2203 Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 128) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 129) 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, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion 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. The camshaft is allowed to rotate up to 30 degrees. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Cam Timing System > Page 2204 Variable Valve Timing Solenoid: Description and Operation Variable Cam Timing (Vct) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 128) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Cam Timing System > Page 2205 Variable Valve Timing Solenoid: Description and Operation Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 129) 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, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion 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. The camshaft is allowed to rotate up to 30 degrees. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2209 Compression Check: Testing and Inspection Compression Test General Remarks NOTE: Removing fuses and disconnecting electrical components causes the Powertrain Control Module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. NOTE: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check the Compression Pressure. WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, 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. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other are both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Bearing: > 06-3-5 > Feb > 06 > Engine - Left Bank Cylinder Head Ticking Noise Camshaft Bearing: Customer Interest Engine - Left Bank Cylinder Head Ticking Noise TSB 06-3-5 02/20/06 CAMSHAFT TICK NOISE - 3.0L 4V ENGINE ONLY FORD: 2001-2005 Taurus 2001-2006 Escape MERCURY: 2001-2005 Sable 2005-2006 Mariner This article supersedes TSB 04-20-8 to update the vehicle model years and Service Procedure. ISSUE Some 2001-2005 Taurus/Sable, 2001-2006 Escape and 2005-2006 Mariner vehicles built prior to 1-17-2006 equipped with the 3.0L 4V Duratec engine may exhibit a ticking noise from the left bank cylinder head, with the engine at normal operating temperature only. ACTION To diagnose, with the engine running and warm (normal operation temperature), using a mechanic's stethoscope determine if the ticking noise is coming from the left hand intake camshaft at cylinder number 6, (Figure 1). If the ticking noise can be verified, refer to the following Service Procedure. SERVICE PROCEDURE 1. Remove the left bank valve cover. Refer to Workshop Manual, Section 303-01B. 2. Rotate the engine clock wise until the cylinder number 6 intake cam lobes are pointing up and the valves are fully closed. 3. Remove all left hand intake cam caps individually and reinstall them finger tight. NOTE THE CAMSHAFT CAPS MUST BE COMPLETELY LIFTED OFF AND THEN SET BACK INTO POSITION. LOOSENING AND RE-TORQUEING CAP BOLTS IS NOT SUFFICIENT. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Bearing: > 06-3-5 > Feb > 06 > Engine - Left Bank Cylinder Head Ticking Noise > Page 2219 4. Torque bolts in sequence shown in Figure 2 to 72 lb-in (8 N.m) excluding cam cap number 8L camshaft cap. 5. Using a screw driver positioned on each side of the top of cam cap number 8L (Figure 3) apply hand pressure and shift cam cap number 8L toward the exhaust side of the cylinder head. 6. While holding cam cap number 8L in the shifted position, torque the fasteners number 9 (inboard) first, to 72 lb-in (8 N.m) then torque fastener number 10 (Figure 3). 7. Install the left hand camshaft cover. Refer to appropriate Workshop Manual, Section 303-01. 8. Fully warm the engine to normal operating temperature to verify the repair. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 060305A 2001-2003 Taurus/Sable: 0.9 Hr. Remove And Install The Camshaft Caps Includes Time To Remove And Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Bearing: > 06-3-5 > Feb > 06 > Engine - Left Bank Cylinder Head Ticking Noise > Page 2220 Install Valve Cover (Do Not Use With 6007A10, 6250AL, 6584AL) 060305A 2004-2005 1.0 Hr. Taurus/Sable: Remove And Install The Camshaft Caps Includes Time To Remove And Install Valve Cover (Do Not Use With 6007A10, 6250AL, 6584AL) 060305A 2001-2006 Escape and 1.2 Hrs. 2005-2006 Mariner: Remove And Install The Camshaft Caps Includes Time To Remove And Install Valve Cover (Do Not Use With 6007A10, 6250AL, 6584AL) DEALER CODING CONDITION BASIC PART NO. CODE 6A267 07 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Bearing: > 06-3-5 > Feb > 06 > Engine - Left Bank Cylinder Head Ticking Noise Camshaft Bearing: All Technical Service Bulletins Engine - Left Bank Cylinder Head Ticking Noise TSB 06-3-5 02/20/06 CAMSHAFT TICK NOISE - 3.0L 4V ENGINE ONLY FORD: 2001-2005 Taurus 2001-2006 Escape MERCURY: 2001-2005 Sable 2005-2006 Mariner This article supersedes TSB 04-20-8 to update the vehicle model years and Service Procedure. ISSUE Some 2001-2005 Taurus/Sable, 2001-2006 Escape and 2005-2006 Mariner vehicles built prior to 1-17-2006 equipped with the 3.0L 4V Duratec engine may exhibit a ticking noise from the left bank cylinder head, with the engine at normal operating temperature only. ACTION To diagnose, with the engine running and warm (normal operation temperature), using a mechanic's stethoscope determine if the ticking noise is coming from the left hand intake camshaft at cylinder number 6, (Figure 1). If the ticking noise can be verified, refer to the following Service Procedure. SERVICE PROCEDURE 1. Remove the left bank valve cover. Refer to Workshop Manual, Section 303-01B. 2. Rotate the engine clock wise until the cylinder number 6 intake cam lobes are pointing up and the valves are fully closed. 3. Remove all left hand intake cam caps individually and reinstall them finger tight. NOTE THE CAMSHAFT CAPS MUST BE COMPLETELY LIFTED OFF AND THEN SET BACK INTO POSITION. LOOSENING AND RE-TORQUEING CAP BOLTS IS NOT SUFFICIENT. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Bearing: > 06-3-5 > Feb > 06 > Engine - Left Bank Cylinder Head Ticking Noise > Page 2226 4. Torque bolts in sequence shown in Figure 2 to 72 lb-in (8 N.m) excluding cam cap number 8L camshaft cap. 5. Using a screw driver positioned on each side of the top of cam cap number 8L (Figure 3) apply hand pressure and shift cam cap number 8L toward the exhaust side of the cylinder head. 6. While holding cam cap number 8L in the shifted position, torque the fasteners number 9 (inboard) first, to 72 lb-in (8 N.m) then torque fastener number 10 (Figure 3). 7. Install the left hand camshaft cover. Refer to appropriate Workshop Manual, Section 303-01. 8. Fully warm the engine to normal operating temperature to verify the repair. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 060305A 2001-2003 Taurus/Sable: 0.9 Hr. Remove And Install The Camshaft Caps Includes Time To Remove And Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Bearing: > 06-3-5 > Feb > 06 > Engine - Left Bank Cylinder Head Ticking Noise > Page 2227 Install Valve Cover (Do Not Use With 6007A10, 6250AL, 6584AL) 060305A 2004-2005 1.0 Hr. Taurus/Sable: Remove And Install The Camshaft Caps Includes Time To Remove And Install Valve Cover (Do Not Use With 6007A10, 6250AL, 6584AL) 060305A 2001-2006 Escape and 1.2 Hrs. 2005-2006 Mariner: Remove And Install The Camshaft Caps Includes Time To Remove And Install Valve Cover (Do Not Use With 6007A10, 6250AL, 6584AL) DEALER CODING CONDITION BASIC PART NO. CODE 6A267 07 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Page 2228 Camshaft Bearing: Specifications RH Camshaft cap bolts 89 inch lbs LH Camshaft cap bolts 89 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Lobe lift Intake (primary) 0.188 inch Intake (secondary) 0.188 inch Exhaust 0.188 inch Lobe lift-allowable lift loss 0.0 inch Valve lift @ zero lash Intake (primary) 0.388 inch Intake (secondary) 0.388 inch Exhaust 0.388 inch Camshaft end play 0.027-0.190 mm Standard 0.001-0.0064 inch Service limit 0.00748 inch Journal to bearing clearance Standard 0.001-0.0029 inch Service limit 0.0047 inch Journal diameters (all) 1.061-1.060 inch Journal inside diameter (cap assembled) 27.012-26.987 mm Bearing inside diameter (all) 1.063 - 1.062 inch RH Camshaft cap bolts 89 inch lbs. LH Camshaft cap bolts 89 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2232 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH Camshaft: Service and Repair LH Camshafts LH Special Tool(s) Removal 1. Remove the water pump belt. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH > Page 2235 2. Using the special tools, remove the water pump drive pulley. 3. Remove the timing drive components. 4. NOTE: In order to assure correct sealing do not scratch the camshaft. Using the special tools, remove the camshaft oil seal. 5. Remove the bolts and the camshaft oil seal retainer. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH > Page 2236 6. CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. Loosen the LH camshaft cap bolts in sequence to allow the camshafts to rise from the cylinder head and remove the caps. 7. Remove the camshafts. Installation Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH > Page 2237 1. NOTE: Be sure camshaft bearing caps are installed in the original positions. Lubricate camshafts with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specification WSS-M2C153-H and carefully position the camshafts into the cylinder head. Align the camshafts as shown. 2. CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps may occur. Lubricate the bearing surfaces of the camshaft bearing caps with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specifications WSS-M2C153-H. Install the bearing caps and loosely install the bolts. 3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specifications WSS-M2C153-H. Install the bearing thrust caps and loosely install the bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH > Page 2238 4. Tighten the bolts in the sequence shown. 5. Install the camshaft oil seal retainer. - Install a new gasket. 6. Install the timing drive components. 7. NOTE: Lubricate the camshaft oil seal with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent, meeting Ford specification WSS-M2C153-H. Using special tools, install a new camshaft oil seal. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH > Page 2239 8. Using the special tool, install the water pump drive pulley. 9. Install the water pump belt. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH > Page 2240 Camshaft: Service and Repair RH Camshafts RH Removal 1. Remove the timing drive components. 2. CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. Loosen the RH camshaft cap bolts in sequence to allow the camshafts to rise from the cylinder head and remove the caps. 3. Remove the camshafts. Installation 1. NOTE: Be sure camshaft bearing caps are installed in the original positions. Lubricate camshafts with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specification WSS-M2C153-H and carefully position the camshafts into the cylinder head. Align the camshafts as shown. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH > Page 2241 2. CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps may occur. Lubricate the bearing surfaces of the camshaft bearing caps with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specifications WSS-M2C153-H and install the bearing caps and loosely install the bolts. 3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specifications WSS-M2C153-H. Install the bearing thrust caps and loosely install the bolts. 4. Tighten the bolts in the sequence shown. 5. Install the timing drive components. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair Hydraulic Lash Adjusters Removal and Installation 1. Remove the camshaft followers. 2. NOTE: Mark the positions of the hydraulic lash adjusters to make sure they are assembled in their original position. Remove the hydraulic lash adjusters. 3. NOTE: Inspect the hydraulic lash adjusters for scoring marks and uneven wear in the bore. Install new lash adjusters if necessary. To install, reverse the removal procedure. Lubricate the hydraulic lash adjusters with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent, meeting Ford specification WSS-M2C153-H. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Roller Followers Special Tool(s) Removal and Installation 1. Remove the LH and RH valve covers. 2. Remove the LH and RH spark plugs. 3. Remove the RH front wheel. 4. Remove the splash shield. 5. Rotate the crankshaft until the camshaft lobe is pointing directly away from the follower. 6. Using the special tool, remove the followers. 7. To install, reverse the removal procedure. - Lubricate the camshaft followers with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specifications WSS-M2C153-H. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting rod bearings Clearance to crankshaft 0.001-0.0025 inch Bearing wall thickness (std) .059 inch 0.250 mm Undersize-Add 0.125 mm to standard or grade 2 thickness. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt Connecting Rod: Specifications Connecting Rod Cap Bolts Stage 1 17 ft. lbs. Stage 2 32 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 2256 Connecting Rod: Specifications Crankshaft Connecting rod journal diameter 1.967-1.968 inch Connecting rod bearings Clearance to crankshaft 0.001-0.0025 inch Bearing wall thickness (std) .059 inch 0.250 mm Undersize-Add 0.125 mm to standard or grade 2 thickness. Connecting Rod Piston pin bore diameter 0.827-0.828 inch Crankshaft bearing bore diameter 2.0872-2.0879 inch Length (center to center) 5.435-5.38 inch Alignment (bore to bore max difference) Twist / per 25 0.0019 per 0.984 inch Pin bore and crank bearing bore must be parallel and in same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 101.5 mm on each side of rod centerline. Band / per 25 0.0014 per 0.984 inch Side clearance (assembled to crank) Standard 0.0039-0.0118 inch Service limit Max 0.0137 inch Piston pin Length 2.382-2.365 inch Diameter 0.0013 inch Pin to piston clearance 0.0001-0.00003 inch Time required for plunger to leak down 1.6 mm of travel with 222N force and leak down fluid in tappet. Pin to rod clearance Standard 0.0001-0.0007 inch Service limit 0.0013 inch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Lower cylinder block bolts and studs Stage 1 18 ft. lbs. Fasteners 1-8 Stage 2 30 ft. lbs. Fasteners 9-19 Stage 3 90° fasteners 1-16 Stage 4 18 ft.lbs. Fasteners 17-22 Crankshaft Main bearing journal diameter 2.467-2.479 inch Connecting rod journal diameter 1.967-1.968 inch Crankshaft free end play .004-.009 inch Crankshaft runout to rear diameter face of cylinder block Max 0.001 inch Main bearings Clearance to Crankshaft-desired 0.0009-0.0001 inch Clearance to Crankshaft-allowable 0.0009-0.0019 inch Bearing wall Thickness-grade 1 0.0983 inch Bearing wall Thickness-grade 2 0.0985 inch Measured at 1.9685 inch from outer perimeter top of piston to the pin axis. Bearing wall Thickness-grade 3 0.0986 inch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft Main bearing journal diameter 2.467-2.479 inch Connecting rod journal diameter 1.967-1.968 inch Crankshaft free end play .004-.009 inch Crankshaft runout to rear diameter face of cylinder block Max 0.001 inch Connecting rod bearings Clearance to crankshaft 0.001-0.0025 inch Bearing wall thickness (std) .059 inch 0.250 mm Undersize-Add 0.125 mm to standard or grade 2 thickness. Main bearings Clearance to Crankshaft-desired 0.0009-0.0001 inch Clearance to Crankshaft-allowable 0.0009-0.0019 inch Bearing wall Thickness-grade 1 0.0983 inch Bearing wall Thickness-grade 2 0.0985 inch Measured at 1.9685 inch from outer perimeter top of piston to the pin axis. Bearing wall Thickness-grade 3 0.0986 inch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Stage 1 86 ft. lbs. Stage 2 Loosen 360° Stage 3 37 ft. lbs. Stage 4 90° Stage 5 90° Stage 6 90° Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2269 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley Special Tool(s) Removal and Installation 1. Remove the accessory drive belt. 2. Remove the splash shield. 3. Using the special tool, remove the crankshaft pulley bolt and washer. 4. Using the damper tool, remove the crankshaft pulley. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2270 Installation 1. NOTE: Seal surfaces must be free of dirt and oil. Apply Silicone Gasket and Sealant F7AZ-19554-EA or equivalent, meeting Ford specification WSE-M4G323-A4, to the end of the keyway slot. 2. NOTE: Lubricate the outside diameter sealing surface of the crankshaft pulley with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent, meeting Ford specification WSS-M2C153-H. Using the special tool, install the crankshaft pulley. 3. Install the bolt and the washer and tighten in four stages. - Stage 1: Tighten to 120 Nm (86 ft. lbs.). - Stage 2: Loosen 360°. - Stage 3: Tighten to 50 Nm (37 ft. lbs.). - Stage 4: Tighten an additional 90°. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2271 4. Install the splash shield. 5. Install the accessory drive belt. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston / Piston diameter Coated grade 1 3.5035-3.5043 inch Measured at 1.9685 inch from outer perimeter top of piston to the pin axis. Coated grade 2 3.5039-3.5048 inch Coated grade 3 3.5043-3.5051 inch Uncoated grade 1 3.50275-3.50314 inch Uncoated grade 2 3.50306-3.50362 inch Uncoated grade 3 3.50432-3.50511 inch Piston to bore clearance 0.0005-0.0009 inch Pin bore diameter (piston) 0.8270-0.8272 inch Ring groove width Compression (top) 0.0484-0.0490 inch Compression (bottom) 0.0602-0.0608 inch Oil ring 0.1192-0.0120 inch Piston pin Length 2.382-2.365 inch Diameter 0.0013 inch Pin to piston clearance 0.0001-0.00003 inch Time required for plunger to leak down 1.6 mm of travel with 222N force and leak down fluid in tappet. Pin to rod clearance Standard 0.0001-0.0007 inch Service limit 0.0013 inch Side clearance Compression (top) 0.0015-0.0029 inch Compression (bottom) 0.0015-0.0033 inch Oil ring Snug Fit Service limit 0.0039 inch Compression (top)-service limit Max 0.0196 inch Compression (bottom)-service limit Max 0.0255 inch Oil ring (steel rail)-service limit Max 0.0354 inch Piston ring gap Compression (top)-gauge diameter 0.0039-0.0098 inch Specification 3.2441 inch diameter gauge. Compression (bottom)-gauge diameter 0.0106-0.0165 inch Oil ring (steel rail)-gauge Diameter 0.0059-0.0255 inch Compression (top)-service limit Max 0.0196 inch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 2275 Compression (bottom)-service limit Max 0.0255 inch Oil ring (steel rail)-service limit Max 0.0354 inch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston pin Length 2.382-2.365 inch Diameter 0.0013 inch Pin to piston clearance 0.0001-0.00003 inch Time required for plunger to leak down 1.6 mm of travel with 222N force and leak down fluid in tappet. Pin to rod clearance Standard 0.0001-0.0007 inch Service limit 0.0013 inch Side clearance Compression (top) 0.0015-0.0029 inch Compression (bottom) 0.0015-0.0033 inch Oil ring Snug Fit Service limit 0.0039 inch Compression (top)-service limit Max 0.0196 inch Compression (bottom)-service limit Max 0.0255 inch Oil ring (steel rail)-service limit Max 0.0354 inch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Ring groove width Compression (top) 0.0484-0.0490 inch Compression (bottom) 0.0602-0.0608 inch Oil ring 0.1192-0.0120 inch Side clearance Compression (top) 0.0015-0.0029 inch Compression (bottom) 0.0015-0.0033 inch Oil ring Snug Fit Service limit 0.0039 inch Compression (top)-service limit Max 0.0196 inch Compression (bottom)-service limit Max 0.0255 inch Oil ring (steel rail)-service limit Max 0.0354 inch Piston ring gap Compression (top)-gauge diameter 0.0039-0.0098 inch Specification 3.2441 inch diameter gauge. Compression (bottom)-gauge diameter 0.0106-0.0165 inch Oil ring (steel rail)-gauge Diameter 0.0059-0.0255 inch Compression (top)-service limit Max 0.0196 inch Compression (bottom)-service limit Max 0.0255 inch Oil ring (steel rail)-service limit Max 0.0354 inch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 2286 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) 1. Remove the Schrader valve cap at the end of the fuel injection supply manifold and attach the Fuel Pressure Gauge. 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. Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. NOTE: Position a suitable container for the fuel to drain into. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 2287 Fuel Pressure Gauge Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Roller Followers Special Tool(s) Removal and Installation 1. Remove the LH and RH valve covers. 2. Remove the LH and RH spark plugs. 3. Remove the RH front wheel. 4. Remove the splash shield. 5. Rotate the crankshaft until the camshaft lobe is pointing directly away from the follower. 6. Using the special tool, remove the followers. 7. To install, reverse the removal procedure. - Lubricate the camshaft followers with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specifications WSS-M2C153-H. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH Valve Cover: Service and Repair LH Valve Cover LH Removal 1. Remove the three nuts and the engine appearance cover. 2. Disconnect the crankcase ventilation tube from the valve cover. 3. Remove the three LH coil-on-plugs. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the coil. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2295 4. Disconnect the wiring harness from the valve cover studs. 5. Remove the engine lift bracket. 6. Position the power steering hose aside. - Remove the bolt. 7. Remove the bolts, studs and the LH valve cover. - Remove and discard the gasket if damaged. Installation 1. Position a new gasket on the valve cover. NOTE: The valve cover must be installed and the bolts tightened within six minutes of applying the sealant. 2. Apply a 5 mm dot of Silicone Gasket Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the front cover to cylinder head joints. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2296 3. Position the valve cover and install the studs and the bolts in the sequence shown. 4. Position the power steering hose and install the bolt. 5. Position the engine lift bracket and install the bolt. 6. Connect the wiring harness to the valve cover studs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2297 7. Install the three LH coils-on-plug. 1 Position the coil. 2 Install the bolts. 3 Connect the electrical connector. 8. Connect the crankcase ventilation tube to the valve cover. 9. Install the three nuts and the engine appearance cover. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2298 Valve Cover: Service and Repair RH Valve Cover RH Removal 1. Remove the upper intake manifold. 2. Remove the RH coils-on-plug. 1 Disconnect the three electrical connectors. 2 Remove the three bolts. 3 Remove the coil. 3. Remove the wiring harness nuts and disconnect the (02) sensor electrical connectors. 4. Remove the radio ignition interference capacitor. 5. Separate the harness from the center locating pins and position aside. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2299 6. Disconnect the crankcase ventilation tube from the valve cover. 7. Remove the bolts, studs and the RH valve cover. - Install the new gasket if damaged. Installation NOTE: The valve cover must be installed and the bolts tightened within six minutes of applying the sealant. 1. Install a new valve cover gasket if damaged. 2. Apply a 5 mm dot of Silicone Gasket Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the front cover to cylinder head joints. 3. Position the valve cover and install the bolt and the studs in the sequence shown. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2300 4. Connect the crankcase ventilation tube to the valve cover. 5. Connect the radio ignition interference capacitor. 6. Connect the (02) sensor electrical connectors and wiring harness to the RH valve cover stud. 7. Install the RH coils-on-plug. 1 Position the coils. 2 Install the three bolts. 3 Connect the electrical connectors. 8. Install the upper intake manifold. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair Valve Spring: Service and Repair Valve Spring Special Tool(s) Removal and Installation 1. Remove the roller followers. 2. 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. Pressurize the cylinder using compressed air. 3. Using the special tool, remove the key, retainer, and valve spring. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Accessory Drive 2.0L Zetec without A/C 2.0L Zetec with A/C Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2308 3.0L (4V) with A/C Water Pump Drive Belt-3.0L (4V) with Tensioner Water Pump Drive Belt-3.0L (4V) without Tensioner Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 following 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 Crack 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2311 Drive Belt: Symptom Related Diagnostic Procedures Symptom Chart Part 1 of 2 Part 2 of 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2312 Drive Belt: Component Tests and General Diagnostics Belt Tensioner-Dynamic 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. Belt Tensioner-Mechanical 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Drive Belt: Service and Repair Drive Belt Accessory Drive Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt > Page 2315 Drive Belt: Service and Repair Water Pump With Tensioner Water Pump Belt-3.0L (4V) with Tensioner Removal and Installation 1. Remove the nuts and the engine appearance cover. 2. Rotate the drive belt tensioner clockwise and remove the water pump belt. 3. To install, reverse the removal procedure. Without Tensioner Water Pump Belt-3.0L (4V) without Tensioner Removal 1. Remove the nuts and the engine appearance cover. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt > Page 2316 2. Rotate the crankshaft clockwise and remove the water pump belt by walking off the pulley. Installation 1. Partially start the water pump belt on the pulley. 2. Rotate the crankshaft clockwise and install the water pump belt by walking on the pulley. 3. Install the engine appearance cover and the nuts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Accessory Drive Belt Tensioner Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner Accessory Drive Belt Tensioner-3.0L (4V) Removal and Installation 1. Remove the accessory drive belt. 2. Remove the bolt and the accessory drive belt tensioner. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Accessory Drive Belt Tensioner > Page 2321 Drive Belt Tensioner: Service and Repair Belt Tensioner-Water Pump Belt Tensioner-Water Pump, 3.0L (4V) Removal and Installation 1. NOTE: If equipped with belt tensioner. Remove the water pump belt. 2. Remove the bolt and the belt tensioner. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair Engine Mount: Service and Repair Engine Support Insulators-Front, RH Special Tool(s) Removal and Installation 1. Remove the engine ground wire. 2. Using the special tools, support the engine. 3. Remove the A/C line bracket bolt and position the A/C lines out of the way. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Page 2325 4. Remove the engine support insulator bolt. 5. Remove the engine support tool. 1 Remove the nut. 2 Remove the bolts and insulator. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure 750 +/- 50 rpm 45 psi Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2334 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Page 2335 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Removal and Installation 1. Remove the oil level indicator. 2. Remove the oil level indicator tube. 1 Remove the stud. 2 Remove the oil level indicator tube. 3. Inspect the O-ring seal at the end of the oil level indicator tube and install a new O-ring seal if necessary. 4. To install, reverse the removal procedure. - Lubricate the O-ring seal with Super Premium SAL 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specification WSS-M2C153-H. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2340 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2341 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2342 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 ............................................................................................................................................ ............................................................. 5.2L (5.5 Qt) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2345 Engine Oil: Fluid Type Specifications Engine Oil Type ....................................................................................................................................................... Super Premium SAE 5W-20 Motor Oil Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair Oil Cooler: Service and Repair Oil Cooler Removal and Installation 1. Drain the engine coolant. 2. Remove the oil pan drain bolt and drain engine oil. 3. Remove the oil filter. 4. Disconnect the coolant hoses at the cooler. 5. Remove the oil cooler. 6. To install, reverse the removal procedure. - Fill the crankcase with SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specification WSS-M2C153-H. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Baffle Oil Pan: Service and Repair Oil Pan Baffle Oil Pan Baffle Removal 1. Remove the oil pump screen cover and tube. 2. Remove the nuts and the oil pan baffle. Installation 1. Position the oil pan baffle and install the nuts. - Tighten the nuts in two stages. - Stage 1: Tighten to 5 Nm (44 inch lbs.). - Stage 2: Tighten 45°. 2. Install the oil pump screen cover and tube. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Baffle > Page 2353 Oil Pan: Service and Repair Oil Pan, Engine Oil Pan Removal 1. Remove the flexible exhaust pipe. 2. Disconnect the downstream catalyst monitor sensor. 3. Drain the oil. 4. Install the drain plug. 5. Remove and discard the oil filter. 6. Remove the 15 bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Baffle > Page 2354 7. Remove the three bolts and the oil pan. Installation CAUTION: Do not use metal scrapers wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. 1. Clean all sealing surfaces on the engine and the oil pan with metal surface cleaner. 2. Position a new gasket on the oil pan. 3. NOTE: Clean and degrease all sealing surfaces with metal surface cleaner. NOTE: The oil pan must be installed and the bolts tightened with in four minutes of sealant application. Apply a 10 mm (0.40 in.) diameter dot of silicone gasket and sealer to the areas indicated. 4. Position the oil pan and gasket and loosely install the bolts in the sequence shown 5. Install the oil pan-to-transaxle bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Baffle > Page 2355 6. Tighten the oil pan bolts in the sequence shown. 7. Lubricate the oil filter O-ring with clean engine oil and install the oil filter. 8. Install the exhaust flexible exhaust pipe. 9. Connect the downstream catalyst monitor. 10. Lower the vehicle. 11. Fill the crankcase with clean engine oil. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Page 2359 Oil Pressure Sender: Service and Repair Oil Pressure Sender Removal and Installation 1. Raise and support the vehicle. 2. Remove the right side splash shield. 3. NOTE: The A/C compressor has been removed for clarity. Remove the oil pressure sender. 1 Disconnect the electrical connector. 2 Remove the sender. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair Oil Pick Up/Strainer: Service and Repair Oil Pump Screen and Pickup Tube Removal 1. Remove the oil pan. 2. Remove the nut, bolts and the oil pump screen and pick-up tube. 3. Remove and inspect the O-ring seal. Discard if damaged. Installation 1. Install the O-ring seal. Use a new seal if necessary. 2. Install the oil pump screen cover and tube. 1 Position the oil pump screen and pick up tube. 2 Install the bolts. 3 Install the nut. - Tighten the nut in two stages. - Stage 1: Tighten to 5 Nm (44 inch lbs.). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Page 2363 - Stage 2: Tighten 45°. 3. Install the oil pan. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 750 +/- 50 rpm 45 psi Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Upper intake manifold bolts 89 inch lbs. Lower intake manifold bolts 89 inch lbs. Throttle body bolt and stud 89 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold: Service and Repair Lower Lower Intake Manifold Removal 1. Disconnect the fuel line spring lock coupling. 2. Remove the upper intake manifold. 3. Disconnect the fuel rail. 1 Disconnect the six fuel injector electrical connectors and wire harness locators. 2 Disconnect the fuel pressure damper vacuum line. 4. Remove the bolts and the lower intake manifold. 5. Remove the fuel rail. 1 Remove the four bolts. 2 Carefully separate the lower intake manifold from the fuel rail. 6. Remove the six fuel injectors from the lower intake manifold. 7. Remove and discard the gaskets if damaged. Installation 1. Install the gaskets in the lower intake manifold. 2. CAUTION: Never use silicone grease. It will clog the fuel injectors. NOTE: Inspect the fuel injector O-ring seals and install new O-ring seals if necessary. Lubricate the O-ring seals lightly with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent, meeting Ford specification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 2373 WSS-M2C914-A and install the fuel injectors into the lower intake manifold. 3. Install the fuel rail. 1 Position the fuel rail. 2 Install the four bolts. 4. Install the lower intake manifold assembly and tighten the bolts in the sequence shown. 5. Connect the fuel rail. 1 Position the wire harness locators and connect the six fuel injectors. 2 Connect the fuel pressure damper vacuum line. 6. Install the upper intake manifold. 7. Connect the fuel line spring lock coupling. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 2374 Intake Manifold: Service and Repair Upper Upper Intake Manifold Removal 1. Remove the air cleaner outlet tube. 1 Remove the crankcase ventilation tube. 2 Loosen the clamps. 3 Remove the air cleaner outlet tube. 2. Remove the three nuts and the engine appearance cover. 3. Disconnect the cables. 1 Disconnect the throttle cable. 2 If equipped, disconnect the speed control cable. 3 Remove the throttle cable bracket bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 2375 4. Disconnect the Throttle Position (TP) sensor and Idle Air Control (IAC) electrical connectors. 5. Disconnect the Exhaust Gas Recirculation (EGR) valve vacuum hose and EGR tube nut. 6. Disconnect the EGR vacuum regulator valve electrical connector and vacuum hose. 7. Disconnect the three vacuum hoses on the back of the intake manifold. 1 Disconnect the chassis vacuum hose. 2 Disconnect the engine vacuum hose. 3 Disconnect the Positive Crankcase Ventilation (PCV) hose. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 2376 8. Disconnect the Vapor Management Valve (VMV) vacuum hose. 9. Disconnect the two electrical connectors attached to the left side of the upper intake manifold. 10. Disconnect the Power Steering Pressure (PSP) sensor electrical connector. 11. Position the transmission vent hose and bracket aside. - Remove the bolt. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 2377 12. Remove the nut from the wire harness. 13. Remove the eight bolts and the upper intake manifold. - Remove and inspect the gaskets. Discard if damaged. - Clean all sealing surfaces. Installation 1. Position the gaskets in the upper intake manifold. 2. Position the upper intake manifold and tighten the bolts in the sequence shown. 3. Connect the PSP electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 2378 4. Position the transmission vent tube and bracket and install the bolt. 5. Position the wire harness and install the nut. 6. Install the two electrical connectors on the left side of the intake manifold. 7. Install the Vapor Management Valve (VMV) vacuum hose. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 2379 8. Connect the three vacuum hoses on the back of the upper intake manifold. 1 Connect the chassis vacuum hose. 2 Connect the engine vacuum hose. 3 Connect the PCV hose. 9. Connect the EGR vacuum regulator valve electrical connector and the vacuum hose. 10. Install the EGR valve vacuum hose and EGR tube nut. 11. Connect the TP sensor and IAC electrical connectors. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 2380 12. Connect the throttle cables. 1 Install the throttle cable bracket bolts. 2 Connect the throttle cable. 3 If equipped, connect the speed control cable. 13. Install the air cleaner outlet tube. 1 Position the air cleaner outlet tube. 2 Install the hoses. 3 Install the clamps. 14. Install the splash shield. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Specifications Camshaft Oil Seal: Specifications Camshaft oil seal retainer bolts 89 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 flexplate. 2. Using the special tools, remove the crankshaft rear oil seal. Installation Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2388 1. NOTE: Lubricate the crankshaft rear oil lips with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specifications WSS-M2C153-H. Using the special tools, install the crankshaft rear oil seal. 2. Install the flexplate. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2393 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2394 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2395 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2396 Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2397 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2398 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 crankshaft pulley. 2. Using the special tool, remove the crankshaft front oil seal. Installation 1. Using the special tool, install the crankshaft front oil seal. 2. Install the crankshaft pulley. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Seals Special Tool(s) Removal 1. Remove the valve spring. 2. NOTE: Camshaft removed for clarity. Remove the valve seal. Installation NOTE: Lubricate the valve guide with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specification WSS-M2C153-H. 1. Using the special tool, install the valve seal. 2. Install the valve spring. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Page 2409 Oil Pressure Sender: Service and Repair Oil Pressure Sender Removal and Installation 1. Raise and support the vehicle. 2. Remove the right side splash shield. 3. NOTE: The A/C compressor has been removed for clarity. Remove the oil pressure sender. 1 Disconnect the electrical connector. 2 Remove the sender. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams Timing Chain: Diagrams CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains. 1. Mark any link to use as the crankshaft timing mark. 2. Starting with the crankshaft timing mark, count 29 links and mark the link. 3. Continue counting to link 42 and mark the link. Crankcase keyway in the 11 o'clock position. Verify that the LH camshafts are correctly positioned. Position the LH timing chain and align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Page 2414 Crankshaft keyway is in the 3 o'clock position. Verify that the RH camshafts are correctly positioned. - Install the RH timing chain and chain guide and install the bolts. - Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Page 2415 CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage. Verify the timing with the following steps. 1. There should be 12 chain links between the camshaft timing marks. 2. There should be 27 chain links between the camshaft and the crankshaft timing marks. 3. There should be 30 chain links between the camshaft and the crankshaft timing marks. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications Timing Chain Guide: Specifications Timing chain guide bolts 18 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Timing chain tensioner bolts 18 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine front cover bolts and studs see note* *Multiple step sequence Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2425 Timing Cover: Service and Repair Engine Front Cover Special Tool(s) Removal 1. Remove the RH and LH valve covers. 2. Remove the oil pan. 3. Remove the generator. 4. Remove the bolt and the Camshaft Position (CMP) sensor. 5. Lower the vehicle. 6. Remove the power steering pump. 7. Install front engine support insulator. 8. Remove the special tool. 9. Raise and support the vehicle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2426 10. Remove the bolt and remove the belt tensioner. 11. Remove the crankshaft pulley. 12. Remove the Crankshaft Position (CKP) sensor. - Disconnect the electrical connector. - Remove the bolt and the sensor. 13. NOTE: Remove the engine front cover with the vehicle raised in the air. Remove the bolts, studs and the engine front cover. Installation CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant. 1. Clean all sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. 2. Install three new gaskets in the front cover. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2427 3. NOTE: The engine front cover must be installed and the bolts tightened within six minutes of applying the sealant. Apply a 6 mm (0.24 inch) diameter dot of Silicone Gasket and Sealer F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the cylinder block, lower cylinder block, and cylinder head mating surfaces. 4. NOTE: Fasteners No. 1, 3, 4, 8, 10, 11, 14, 15 and 16 are studs. Position the cover and install the studs and bolts in the sequence shown. 5. Install the (CKP) sensor and connect the electrical connector. 6. Install the crankshaft pulley. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2428 7. Install the tensioner and bolt. 8. Install the generator. 9. Install the oil pan. 10. Lower the vehicle. 11. Install the special tool. 12. Remove the front engine support insulator Engine Support Insulators-Front, RH. 13. Install the radio ignition interference capacitor. 14. Install the power steering pump. 15. Install the RH and LH Valve cover. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Cam Timing System Variable Valve Timing Solenoid: Description and Operation Variable Cam Timing System Overview The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the combustion chamber. The residual gases cool the combustion chamber and are inert when mixed with the incoming fresh charge of fuel and air. This results in better fuel economy and lower Nitrogen Oxides (NOx) and Hydrocarbons (HC) the engine produces. The Exhaust Gas Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature. Variable Cam Timing Variable Cam Timing System The Variable Cam Timing (VCT) System consists of the control solenoid, five-tooth pulse ring (4+1) on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP) sensor, Powertrain Control Module (PCM) (Figure 127). 1. The powertrain control module (PCM) receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, camshaft position (CMP) sensor, mass air flow (MAF) sensor and crankshaft position (CKP) sensor for determining the operating conditions of the engine. 2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are met. The PCM disables the VCT system if a fault is detected. 3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse ring mounted on the exhaust camshaft. Relative cam position is calculated by measuring the time between the rising edge of Profile Ignition Pickup (PIP) and the falling edge of VCT pulse. 4. The PCM continually calculates a cam position error value based on the difference between the desired and actual position and a duty cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit. 5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a rotation motion from the helical mechanism in the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve to correct for cam position error. Hardware Variable Cam Timing (VCT) Solenoid Valve Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Cam Timing System > Page 2434 Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 128) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 129) 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, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion 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. The camshaft is allowed to rotate up to 30 degrees. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Cam Timing System > Page 2435 Variable Valve Timing Solenoid: Description and Operation Variable Cam Timing (Vct) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 128) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Cam Timing System > Page 2436 Variable Valve Timing Solenoid: Description and Operation Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 129) 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, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion 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. The camshaft is allowed to rotate up to 30 degrees. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions Fuel Pressure Test Port: 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. ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 2442 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 2443 Fuel Pressure Test Port: 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 pressure. 2. Remove the pressure relief valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 730 - 750 RPM Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2455 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) 1. Remove the Schrader valve cap at the end of the fuel injection supply manifold and attach the Fuel Pressure Gauge. 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. Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. NOTE: Position a suitable container for the fuel to drain into. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2456 Fuel Pressure Gauge Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications V6 Firing Order: 1 4 2 5 3 6 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 2460 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark plug gap..................................................................................................................................... ................................1.3 - 1.4 mm (0.052 - 0.056 inch) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 2472 Spark Plug: Specifications Torque Spark plugs........................................................................................................................................... ........................................................15 Nm (11 Lb-Ft) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2473 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2474 Spark Plug: Application and ID Spark plug............................................................................................................................................ ...................................................................AWSF-32F Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2475 Spark Plug: Service and Repair REMOVAL 1. Remove the ignition coil-on-plugs. 2. Remove the LH and RH spark plugs. NOTE: LH shown, RH similar. 3. Inspect the spark plugs. INSTALLATION 1. To install, the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2479 Compression Check: Testing and Inspection Compression Test General Remarks NOTE: Removing fuses and disconnecting electrical components causes the Powertrain Control Module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. NOTE: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check the Compression Pressure. WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, 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. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other are both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water pump bolts 18 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2483 Water Pump: Service and Repair Water Pump-3.0L (4V) Removal and Installation 1. Drain the engine cooling system. 2. Remove the air cleaner outlet tube. 3. Remove the water pump belt tensioner, if equipped. 4. Disconnect the three hoses. 5. Remove the bolts and the water pump assembly. 6. Separate the water pump from the water pump housing. 7. NOTE: Clean and inspect the sealing surfaces. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Actuators and Solenoids - Cooling System > Hydraulic Cooling Fan Solenoid Valve > Component Information > Description and Operation > PCM Outputs Hydraulic Cooling Fan Solenoid Valve: Description and Operation PCM Outputs Visctronic Drive Fan (VDF) Visctronic Drive Fan (VDF) Visctronic Drive Fan (VDF) Clutch The primary purpose for the Visctronic Drive Fan (VDF) clutch is to optimize fan energy (i.e. improved fuel economy) while meeting cooling performance requirements. Successful optimization will also minimize objectionable fan noise. The operation is similar to the existing viscous fan clutch, except viscous fluid flow is controlled by a Pulse Width Modulated (PWM) solenoid versus a bi-metal temperature sensor on the front of the clutch. The VDF consists of three main elements, a working chamber, a reservoir chamber, and a Fan Speed Sensor (FANSS). A fluid port valve controls fluid flow from the reservoir into the working chamber. Once viscous fluid is in the working chamber, "shearing" of the fan clutch fluid will result in fan rotation. The valve is activated via a pulse width modulated (PWM) output signal from the PCM. By opening and closing the fluid port valve, the PCM can control approximate fan speed. Fan speed is monitored via a Hall-Effect sensor and is read by the PCM for closed loop operation. The PCM will optimize the VDF fan speed based upon CHT, TFT, or AT cooling requirements. When either of these inputs is demanding increased fan speed for vehicle cooling, the PCM will monitor the Hall Effect Fan Speed Sensor (FANSS), and output the resultant PWM signal to the fluid port valve thus controlling to the required fan speed. Fan Control Fan Control TAURUS/SABLE: PCM FC Output State For Cooling Fan Speeds Chart ESCAPE: PCM FC Output State For Cooling Fan Speeds Chart The PCM monitors certain parameters (such as engine coolant temperature, vehicle speed, A/C on/off status, A/C pressure, etc) to determine engine Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Actuators and Solenoids - Cooling System > Hydraulic Cooling Fan Solenoid Valve > Component Information > Description and Operation > PCM Outputs > Page 2490 cooling fan needs. The PCM controls the fan operation through the Fan Control (FC) (single speed fan applications), Low Fan Control (LFC), Medium Fan Control (MFC) and/or High Fan Control (HFC) outputs. Although the PCM output circuits for three speed tans are called low, medium and high fan control (FC), cooling fan speed is controlled by a combination of these outputs. Refer to the table. Hydraulic Cooling Fan Drive Hydraulic Cooling Fan Drive Hydraulic Cooling Fan Pump With Integral Solenoid The system consists of an engine-driven pump with an integral solenoid (Figure 49) on the pump that is triggered by the powertrain control module (PCM). Fan speed is controlled by adjusting current to the solenoid, which then changes the fluid flow to the hydraulic motor. More current means the solenoid opens up, allowing higher pressure to increase the fan speed. The fan always turns due to solenoid current leakage, even in cold engine cases. The motor is driven by the pump. It contains a shaft on which the fan mounts. The motor also contains quick connect fittings for the high pressure lines. The cooler is similar to the power steering cooler (same purpose and function, to keep the fluid cool). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info > Page 2495 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info > Page 2496 Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info > Page 2497 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling system refill capacities (3.0L 4V) 10.5 quart Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2500 Coolant: Fluid Type Specifications Type Motorcraft Premium Engine Coolant Caution: Do not mix coolant types. Motorcraft Premium Gold Engine Coolant Motorcraft Premium Cooling System Flush Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > 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 2509 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > 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 2515 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Page 2516 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair Bypass Tube-3.0L (4V) Removal and Installation 1. Drain the engine Cooling System. 2. Remove the air cleaner outlet tube. 3. Disconnect the five hoses from the thermostat housing and remove the thermostat housing. 4. Disconnect the Engine Coolant Temperature (ECT) sensor from the bypass tube. 5. Remove the bolt, stud, and the water bypass tube. 6. NOTE: Clean and inspect the sealing surfaces. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2528 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2534 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > Page 2535 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Motor 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Motor 1 > Page 2541 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay Radiator Cooling Fan Motor Relay: Locations Cooling Fan Low Relay Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2546 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2547 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2548 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2549 Radiator Cooling Fan Motor Relay: Locations High Speed Fan Control Relay 1 Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2550 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2551 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2552 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2553 Radiator Cooling Fan Motor Relay: Locations High Speed Fan Control Relay 2 Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2554 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2555 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2556 Radiator Cooling Fan Motor Relay: Locations Medium Speed Fan Control Relay View 151-12 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2557 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2560 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2561 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2562 Radiator Cooling Fan Motor Relay: Diagrams Medium Speed Fan Control Relay Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 2563 Radiator Cooling Fan Motor Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 2564 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Resistor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair Cooling Fan Removal and Installation 1. Disconnect the battery ground cable. 2. Position the hood latch out of the way. 3. If equipped, remove the upper radiator tie strap. 4. Raise and support the vehicle. 5. Remove the lower center support bolt and the lower fan bolts. 6. Lower the vehicle. 7. Remove the upper center support bolt and the lower fan bolt. 8. Disconnect the LH fan electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Page 2571 9. Remove the LH and RH upper radiator supports. 10. Tilt the radiator forward for clearance. 11. Remove the three bolts and the LH cooling fan. 12. If necessary remove the bolt and disconnect the electrical connector, remove the RH fan. 13. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation > PCM Output Fan Clutch: Description and Operation PCM Output Fan Control Fan Control TAURUS/SABLE: PCM FC Output State For Cooling Fan Speeds Chart ESCAPE: PCM FC Output State For Cooling Fan Speeds Chart The PCM monitors certain parameters (such as engine coolant temperature, vehicle speed, A/C on/off status, A/C pressure, etc) to determine engine cooling fan needs. The PCM controls the fan operation through the Fan Control (FC) (single speed fan applications), Low Fan Control (LFC), Medium Fan Control (MFC) and/or High Fan Control (HFC) outputs. Although the PCM output circuits for three speed tans are called low, medium and high fan control (FC), cooling fan speed is controlled by a combination of these outputs. Refer to the table. Hydraulic Cooling Fan Drive Hydraulic Cooling Fan Drive Hydraulic Cooling Fan Pump With Integral Solenoid The system consists of an engine-driven pump with an integral solenoid (Figure 49) on the pump that is triggered by the powertrain control module (PCM). Fan speed is controlled by adjusting current to the solenoid, which then changes the fluid flow to the hydraulic motor. More current means the solenoid opens up, allowing higher pressure to increase the fan speed. The fan always turns due to solenoid current leakage, even in cold engine cases. The motor is driven by the pump. It contains a shaft on which the fan mounts. The motor also contains quick connect fittings for the high pressure Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation > PCM Output > Page 2576 lines. The cooler is similar to the power steering cooler (same purpose and function, to keep the fluid cool). Visctronic Drive Fan (VDF) Visctronic Drive Fan (VDF) Visctronic Drive Fan (VDF) Clutch The primary purpose for the Visctronic Drive Fan (VDF) clutch is to optimize fan energy (i.e. improved fuel economy) while meeting cooling performance requirements. Successful optimization will also minimize objectionable fan noise. The operation is similar to the existing viscous fan clutch, except viscous fluid flow is controlled by a Pulse Width Modulated (PWM) solenoid versus a bi-metal temperature sensor on the front of the clutch. The VDF consists of three main elements, a working chamber, a reservoir chamber, and a Fan Speed Sensor (FANSS). A fluid port valve controls fluid flow from the reservoir into the working chamber. Once viscous fluid is in the working chamber, "shearing" of the fan clutch fluid will result in fan rotation. The valve is activated via a pulse width modulated (PWM) output signal from the PCM. By opening and closing the fluid port valve, the PCM can control approximate fan speed. Fan speed is monitored via a Hall-Effect sensor and is read by the PCM for closed loop operation. The PCM will optimize the VDF fan speed based upon CHT, TFT, or AT cooling requirements. When either of these inputs is demanding increased fan speed for vehicle cooling, the PCM will monitor the Hall Effect Fan Speed Sensor (FANSS), and output the resultant PWM signal to the fluid port valve thus controlling to the required fan speed. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation > Page 2577 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Hydraulic Cooling Fan Solenoid Valve > Component Information > Description and Operation > PCM Outputs Hydraulic Cooling Fan Solenoid Valve: Description and Operation PCM Outputs Visctronic Drive Fan (VDF) Visctronic Drive Fan (VDF) Visctronic Drive Fan (VDF) Clutch The primary purpose for the Visctronic Drive Fan (VDF) clutch is to optimize fan energy (i.e. improved fuel economy) while meeting cooling performance requirements. Successful optimization will also minimize objectionable fan noise. The operation is similar to the existing viscous fan clutch, except viscous fluid flow is controlled by a Pulse Width Modulated (PWM) solenoid versus a bi-metal temperature sensor on the front of the clutch. The VDF consists of three main elements, a working chamber, a reservoir chamber, and a Fan Speed Sensor (FANSS). A fluid port valve controls fluid flow from the reservoir into the working chamber. Once viscous fluid is in the working chamber, "shearing" of the fan clutch fluid will result in fan rotation. The valve is activated via a pulse width modulated (PWM) output signal from the PCM. By opening and closing the fluid port valve, the PCM can control approximate fan speed. Fan speed is monitored via a Hall-Effect sensor and is read by the PCM for closed loop operation. The PCM will optimize the VDF fan speed based upon CHT, TFT, or AT cooling requirements. When either of these inputs is demanding increased fan speed for vehicle cooling, the PCM will monitor the Hall Effect Fan Speed Sensor (FANSS), and output the resultant PWM signal to the fluid port valve thus controlling to the required fan speed. Fan Control Fan Control TAURUS/SABLE: PCM FC Output State For Cooling Fan Speeds Chart ESCAPE: PCM FC Output State For Cooling Fan Speeds Chart The PCM monitors certain parameters (such as engine coolant temperature, vehicle speed, A/C on/off status, A/C pressure, etc) to determine engine Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Hydraulic Cooling Fan Solenoid Valve > Component Information > Description and Operation > PCM Outputs > Page 2582 cooling fan needs. The PCM controls the fan operation through the Fan Control (FC) (single speed fan applications), Low Fan Control (LFC), Medium Fan Control (MFC) and/or High Fan Control (HFC) outputs. Although the PCM output circuits for three speed tans are called low, medium and high fan control (FC), cooling fan speed is controlled by a combination of these outputs. Refer to the table. Hydraulic Cooling Fan Drive Hydraulic Cooling Fan Drive Hydraulic Cooling Fan Pump With Integral Solenoid The system consists of an engine-driven pump with an integral solenoid (Figure 49) on the pump that is triggered by the powertrain control module (PCM). Fan speed is controlled by adjusting current to the solenoid, which then changes the fluid flow to the hydraulic motor. More current means the solenoid opens up, allowing higher pressure to increase the fan speed. The fan always turns due to solenoid current leakage, even in cold engine cases. The motor is driven by the pump. It contains a shaft on which the fan mounts. The motor also contains quick connect fittings for the high pressure lines. The cooler is similar to the power steering cooler (same purpose and function, to keep the fluid cool). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2587 Coolant Temperature Sensor/Switch (For Computer): Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2588 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2589 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Partially drain the cooling system. 2. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the electrical connector. 2 Unclip and remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Diagrams > Page 2593 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. See: Powertrain Management/Description and Operation/Powertrain Control Software Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2602 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2603 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2609 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2610 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service Precautions > Technician Safety Information > Page 2613 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service Precautions > Page 2614 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service Precautions > Page 2615 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service Precautions > Page 2616 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service Precautions > Page 2617 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2626 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2627 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2633 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2634 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 2635 Heater Hose: Service and Repair REMOVAL 1. Drain the engine coolant. 2. Disconnect the heater hoses from the heater core. 3. Disconnect the heater outlet hose from the water hose connection. 4. Disconnect the heater hose connection from the engine. 5. Remove the heater hose from the engine compartment. 6. Disconnect the heater hoses from the heater hose junction. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair Radiator: Service and Repair Radiator Removal and Installation All vehicles 1. Drain the engine cooling system. 2. Raise and support the vehicle. 3. Remove the lower splash shields. Vehicles with 2.0L Zetec engines 4. Disconnect the lower radiator hose and the degas return hose. Vehicles with 3.0L (4V) engines 5. Disconnect the lower radiator hose, the high pressure transmission line and the degas return hose. All vehicles 6. Lower the vehicle. Vehicles with 2.0L Zetec engines Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2639 7. Disconnect the remaining coolant hose connections. Vehicles with 3.0L (4V) engines 8. Disconnect the transmission return line. 9. Disconnect the upper radiator hose and degas supply hose. All vehicles Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2640 10. Position the hood latch assemble out of the way. 11. Remove the two bolts and the center support. 12. Remove the two top bolts retaining the cooling fan to the radiator. 13. Remove the upper radiator support brackets, and remove the radiator from the vehicle. 14. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay Radiator Cooling Fan Motor Relay: Locations Cooling Fan Low Relay Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2646 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2647 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2648 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2649 Radiator Cooling Fan Motor Relay: Locations High Speed Fan Control Relay 1 Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2650 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2651 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2652 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2653 Radiator Cooling Fan Motor Relay: Locations High Speed Fan Control Relay 2 Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2654 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2655 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2656 Radiator Cooling Fan Motor Relay: Locations Medium Speed Fan Control Relay View 151-12 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan Low Relay > Page 2657 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2660 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2661 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2662 Radiator Cooling Fan Motor Relay: Diagrams Medium Speed Fan Control Relay Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 2663 Radiator Cooling Fan Motor Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 2664 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2674 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2680 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Page 2681 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2686 Coolant Temperature Sensor/Switch (For Computer): Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2687 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2688 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Partially drain the cooling system. 2. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the electrical connector. 2 Unclip and remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Diagrams > Page 2692 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. See: Powertrain Management/Description and Operation/Powertrain Control Software Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat starts to open (3.0L 4V) 194 - 200 Fahrenheit Thermostat fully open (3.0L 4V) 223 Fahrenheit Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2696 Thermostat: Description and Operation Thermostat Heater Control Thermostat Assembly With Heater Control The primary objective for the thermostat heater control is for improvement in the economy and thermal efficiency. The system consists of a high temperature (98°C/208°F in lieu of a 90°C/194°F) thermostat (Figure 50) that has a resistive heater within the wax element. The heater is controlled by the PCM dependent on engine speed, throttle position, engine load, vehicle speed, air charge temperature, transmission oil temperature and engine coolant temperature. During low speed, low load and low air charge temperature conditions, the thermostat heater is OFF and the engine is allowed to operate at an elevated coolant temperature. This should result in lower internal friction and higher thermal efficiency, both leading to improved fuel economy. During high speed, high load, high temperature conditions (air charge, transmission oil or engine coolant), the PCM output is energized with a duty cycle to the thermostat heater. This heats the wax and forces the thermostat to rapidly open wider allowing extra coolant to flow from the radiator. This will reduce the coolant temperature and improve with performance demand. It should be noted that the heater is only capable of supplying a SMALL amount of additional heat to the wax element; it is NOT capable of opening the thermostat alone. The thermostat is 100% duty cycle for short calibrated time and than the duty cycle is reduce to a maximum of 70% on and 30% off. Approximately, unheated, the thermostat will begin to open at a coolant temperature of 98°C (208°F) and will be fully open at 115°C (239°F). Energizing the heater will reduce the opening temperature to about 80°C (176°F) and the fully open temperature to 110°C (230°F). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2697 Thermostat: Service and Repair Thermostat-3.0L (4V) Removal and Installation 1. Drain the engine cooling system. 2. NOTE: The appearance cover is shown removed for clarity. Separate the thermostat housing. 3. Remove the thermostat and the O-ring seal from the thermostat housing. 4. NOTE: Clean and inspect the sealing surfaces. To install reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water pump bolts 18 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2701 Water Pump: Service and Repair Water Pump-3.0L (4V) Removal and Installation 1. Drain the engine cooling system. 2. Remove the air cleaner outlet tube. 3. Remove the water pump belt tensioner, if equipped. 4. Disconnect the three hoses. 5. Remove the bolts and the water pump assembly. 6. Separate the water pump from the water pump housing. 7. NOTE: Clean and inspect the sealing surfaces. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Catalyst and Exhaust Systems Catalytic Converter: Description and Operation Catalyst and Exhaust Systems Overview Generic Catalyst And Exhaust System The Catalytic Converter and Exhaust Systems (Figure 133) 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 (CO2) 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, upstream Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD II) system. (Refer to OBD II Monitors to Catalyst Efficiency Monitor-Federal Test Procedure for specific information.) 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. TWC Conversion Efficiency Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Catalyst and Exhaust Systems > Page 2707 TWC Conversion Efficiency Chart 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. Devations outside of this window will greatly decrease the conversion efficiency (Figure 134). For example a rich mixture will decrease the HC and CO conversion efficiency while a lean mixture will decreases the NOx conversion efficiency. 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 and than on in the muffler. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. Hardware The downstream HO2S may be located after the light off catalyst or underbody 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, refer to 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 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. Upstream Heated and Downstream Heated Oxygen Sensors 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.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Catalyst and Exhaust Systems > Page 2708 atmosphere. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Catalyst and Exhaust Systems > Page 2709 Catalytic Converter: Description and Operation Catalytic Converter 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2710 Catalytic Converter: Service and Repair Catalytic Converter-3.0L (4V) Removal and Installation 1. Raise and support the vehicle. 2. Remove and discard the nuts. ^ Discard the gasket. 3. Remove the U-bolt, disconnect the catalytic converter from the hanger. 4. Remove and discard the nuts between main silencer and after silencer pipe. 5. Remove converter and main silencer together. 6. Remove converter from main silencer on the floor. 7. To install, reverse the removal procedure. ^ Install a new gasket. ^ Install new nuts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications RH exhaust manifold nuts 15 ft. lbs. LH exhaust manifold nuts 15 ft. lbs. LH Exhaust Manifold Bolt Tightening Sequence Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2714 Exhaust Manifold: Description and Operation Exhaust Manifold/Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH Exhaust Manifold: Service and Repair LH Exhaust Manifold LH Removal 1. Remove the LH Heated Oxygen Sensor (HO2S) and the LH catalyst monitor. 2. Remove the bolts and the splash shield. 3. Remove the exhaust crossover and position aside. 4. Remove the accessory drive belt. 5. Remove the A/C compressor bolts and position aside. 6. Remove the nuts and LH exhaust manifold and discard the gasket. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 2717 Installation LH Exhaust Manifold Bolt Tightening Sequence 1. Position a new gasket and tighten the exhaust manifold in the sequence shown. 2. Position the A/C compressor and install the bolts. 3. Install the accessory drive belt. 4. Install the exhaust crossover. 5. Install the splash shield. 6. Install the LH HO2S and the LH catalyst monitor. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 2718 Exhaust Manifold: Service and Repair RH Exhaust Manifold RH Removal 1. Remove the Exhaust Gas Recirculation (EGR) tube. 2. Remove the generator. 3. Disconnect and remove the RH Heated Oxygen Sensor (HO2S). 4. Remove the exhaust flexible pipe. 5. Remove the RH manifold. ^ Discard the gasket. Installation 1. Position a new gasket and install the exhaust manifold nuts in the sequence shown. 2. Install the RH HO2S. 3. Install the exhaust flexible pipe. 4. Install the generator. 5. Install the EGR tube. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Description and Operation Exhaust Pipe: Description and Operation 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Description and Operation > Page 2722 Exhaust Pipe: Service and Repair Exhaust Flexible Pipe Removal and Installation 1. Raise and support the vehicle. 2. Remove the RH catalyst monitor. 3. Remove and discard the two nuts and separate the flexible Y-pipe from the manifold. 4. Remove and discard the nuts. ^ Discard the gasket. 5. Remove the nuts. ^ Discard the gasket. 6. Remove the flexible pipe. ^ Disconnect from the hanger. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Description and Operation > Page 2723 7. To install, reverse the removal procedure. ^ Install a new gasket. ^ Install new nuts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Description and Operation Muffler: Description and Operation 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Description and Operation > Page 2727 Muffler: Service and Repair Muffler Removal and Installation 1. Raise and support the vehicle. 2. Remove the U-bolt. 3. Remove the nuts and the muffler. ^ Discard the gasket. ^ Discard the nuts. 4. To install, reverse the removal procedure. ^ Install a new gasket. ^ Install new nuts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Powertrain 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 2738 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 2739 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2740 View 151-11 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2741 Powertrain Control Module: Diagrams Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2742 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2743 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2744 Powertrain Control Module: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2748 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2749 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2750 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2751 Powertrain Control Module Power Relay: Testing and Inspection Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2752 Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation Solid State Relay Solid State Relay The solid state relay (Figure 124) 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). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation Fuel Pump Driver Module Applications Fuel Pump Driver Module Duty Cycle Signals The Fuel Pump Driver Module (FPDM) communicates diagnostic information to the powertrain control module (PCM) through the Fuel Pump Monitor (FPM) circuit. This information is sent by the FPDM as a duty cycle signal. The three duty cycle signals that may be sent are listed in the table. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2764 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2765 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2766 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2767 Fuel Pump Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2768 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2772 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2773 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2774 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2775 Powertrain Control Module Power Relay: Testing and Inspection Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2776 Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2781 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2782 View 151-39 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2783 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2784 Ignition Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2785 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation Thermal Manifold Absolute Pressure Sensor Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 40) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2794 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2795 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2796 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2797 Mass Air Flow 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2801 Camshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 2804 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 2805 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation Clutch Pedal Position Switch Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation > Page 2809 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2813 Coolant Temperature Sensor/Switch (For Computer): Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2814 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2815 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Partially drain the cooling system. 2. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the electrical connector. 2 Unclip and remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2819 Crankshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor 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 powertrain control module (PCM). The trigger 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 trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 25). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 2822 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 2823 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the bolts and the right front lower splash shield. 3. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams > Page 2827 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. See: Description and Operation/Powertrain Control Software Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2831 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline fuel tank pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2832 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2833 ^ Carry out a leak test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/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/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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors (Figure 33) and integrated Mass Air Flow (MAF) type (Figure 36), are thermistor devices in which resistance changes with temperature The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged vehicles use (2) IAT sensors. Both sensors are thermistor type devices and operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Currently two types of IAT2 sensors are used. A screw in type (Figure 33) and an integrated type, witch is part of the Thermal Manifold Absolute Pressure (TMAP) sensor (Figure 40). The TMAP sensor consists of a IAT thermistor and a Manifold Absolute Pressure (MAP) sensor. The thermistor portion of the TMAP is used for IAT2 function and operates in the same manner as a non-integrated IAT2. For additional information on the MAP portion of the TMAP, refer to the Thermal Manifold Absolute Pressure Sensor description and operation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2840 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2841 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2842 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the bolt and the KS. NOTE: The KS is located on the RH side of the cylinder block INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature Engine Oil Temperature (EOT) Sensor The Engine Oil Temperature (EOT) sensor (Figure 29) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the engine coolant temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2851 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2852 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2853 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2854 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2855 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2856 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2857 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 Heated 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2865 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2866 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2867 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2868 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2869 Heated Oxygen Sensor: Connector Views Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2870 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 2871 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input Heated Oxygen Sensor: Description and Operation PCM Input Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 32) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input > Page 2874 Heated Oxygen Sensor: Description and Operation Upstream Heated and Downstream Heated Oxygen Sensors Upstream Heated and Downstream Heated Oxygen Sensors 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.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH Heated Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) LH EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Raise and support the vehicle. 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH > Page 2877 Heated Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) RH EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 2. Raise and support the vehicle. 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH > Page 2878 Heated Oxygen Sensor: Service and Repair Catalyst Monitor Sensor LH EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Raise and support the vehicle. 2. Disconnect the catalyst monitor sensor electrical connector. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH > Page 2879 Heated Oxygen Sensor: Service and Repair Catalyst Monitor Sensor RH 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams Power Steering Pressure Switch: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Page 2883 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Power Steering Pressure (PSP) Switch The Power Steering Pressure (PSP) switch (Figure 37) monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Page 2884 Power Steering Pressure Switch: Service and Repair REMOVAL 1. Remove the Power Steering Pressure (PSP) switch. 1 Disconnect the electrical connector. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2893 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2894 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2895 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2896 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2897 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2903 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2904 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2905 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2906 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2907 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2912 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2913 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2914 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2920 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2921 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2922 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2923 View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2924 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2925 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) 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 aluminum 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2926 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2927 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2931 Throttle Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2932 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2933 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the nuts and the engine appearance cover. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the sensor NOTE: Air cleaner outlet tube is removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Torque Specifications Transmission range (TR) sensor bolts ................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2937 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2938 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2939 Digital Transmission Range 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2940 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2941 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2942 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input Vehicle Speed Sensor: Description and Operation PCM Input Vehicle Speed Sensor Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 44) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input > Page 2948 Vehicle Speed Sensor: Description and Operation PCM Output Powertrain Control Module - Vehicle Speed Output (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH ( 1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2958 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2959 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2960 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2961 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2962 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2968 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2969 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2970 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2971 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2972 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2977 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2978 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2979 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 2985 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 2986 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 2987 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2988 View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2989 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2990 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) 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 aluminum 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2991 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2992 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2997 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2998 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2999 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3000 Mass Air Flow 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3004 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3005 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 30) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor 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. Fuel Rail Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 31) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor Engine Fuel Temperature (EFT) Sensor The Engine Fuel Temperature (EFT) sensor (Figure 28) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EFT sensor measures the temperature 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3012 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3013 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3014 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 151-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3018 Throttle Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3019 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3020 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the nuts and the engine appearance cover. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the sensor NOTE: Air cleaner outlet tube is removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3025 Camshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 3028 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 3029 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3033 Crankshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor 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 powertrain control module (PCM). The trigger 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 trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 25). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 3036 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3037 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the bolts and the right front lower splash shield. 3. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the upper steering column shroud. 3. Remove the screws and the lower steering column shroud. 4. Turn the ignition key to the ON position. 5. Using a small tool, depress the ignition lock cylinder release button and pull the ignition lock cylinder out. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3045 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3046 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3047 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the bolt and the KS. NOTE: The KS is located on the RH side of the cylinder block INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions Fuel Pressure Test Port: 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. ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3053 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3054 Fuel Pressure Test Port: 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 pressure. 2. Remove the pressure relief valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 730 - 750 RPM Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3066 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) 1. Remove the Schrader valve cap at the end of the fuel injection supply manifold and attach the Fuel Pressure Gauge. 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. Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. NOTE: Position a suitable container for the fuel to drain into. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3067 Fuel Pressure Gauge Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications V6 Firing Order: 1 4 2 5 3 6 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3071 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark plug gap..................................................................................................................................... ................................1.3 - 1.4 mm (0.052 - 0.056 inch) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 3083 Spark Plug: Specifications Torque Spark plugs........................................................................................................................................... ........................................................15 Nm (11 Lb-Ft) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3084 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3085 Spark Plug: Application and ID Spark plug............................................................................................................................................ ...................................................................AWSF-32F Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3086 Spark Plug: Service and Repair REMOVAL 1. Remove the ignition coil-on-plugs. 2. Remove the LH and RH spark plugs. NOTE: LH shown, RH similar. 3. Inspect the spark plugs. INSTALLATION 1. To install, the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3090 Compression Check: Testing and Inspection Compression Test General Remarks NOTE: Removing fuses and disconnecting electrical components causes the Powertrain Control Module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. NOTE: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check the Compression Pressure. WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, 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. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other are both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation Thermal Manifold Absolute Pressure Sensor Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 40) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3098 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3099 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3100 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3101 Mass Air Flow 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors (Figure 33) and integrated Mass Air Flow (MAF) type (Figure 36), are thermistor devices in which resistance changes with temperature The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged vehicles use (2) IAT sensors. Both sensors are thermistor type devices and operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Currently two types of IAT2 sensors are used. A screw in type (Figure 33) and an integrated type, witch is part of the Thermal Manifold Absolute Pressure (TMAP) sensor (Figure 40). The TMAP sensor consists of a IAT thermistor and a Manifold Absolute Pressure (MAP) sensor. The thermistor portion of the TMAP is used for IAT2 function and operates in the same manner as a non-integrated IAT2. For additional information on the MAP portion of the TMAP, refer to the Thermal Manifold Absolute Pressure Sensor description and operation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering Auxiliary Air Valve (Idle Speed): Customer Interest Engine Controls/A/T - Unstable Idle/Shuddering TSB 06-11-7 06/12/06 2001-2005 ESCAPE 3.0L UNSTABLE IDLE - 2001-2003 ESCAPE 3.0L AUTOMATIC TRANSAXLE SHUDDER - MEXICO ONLY FORD: 2001-2005 Escape ISSUE Some 2001-2005 Escape vehicles equipped with a 3.0L engine may exhibit idle speeds outside the specified range. Some 2001-2003 Escape vehicles equipped with a 3.0L engine and CD4E automatic transaxle may exhibit a transmission shudder. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. If the concern is a 2001-2005 Escape with idle speeds outside the specified range: a. Install a new idle air control (IAC) valve with jumper harness included in the kit. The new Denso brand IAC will be installed with the electrical connector facing the opposite direction of the original (Hitachi) valve which is why the jumper harness is required. The original (Hitachi) IAC connector faces the front of the vehicle while the new Denso IAC connector faces toward the rear of the vehicle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 3113 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 3114 b. Referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the powertrain control module (PCM) using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 2. If the concern is a 2001 - 2003 Escape with transaxle shudder, drain, flush and refill the transmission fluid with MERCON(R) Multi-Purpose Automatic Transmission Fluid. Then, referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the PCM using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 3. When reprogramming the PCM use blank path programming. Select the proper file from the chart and manually enter the PCM part number or tear tag number to obtain the updated calibration file. To Perform Blank Path Programming: 1. Connect WDS/IDS to vehicle. 2. Select "16 pin", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 5. 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. 6. Screen shows to turn ignition ON. Keep ignition in the "OFF" position, press TICK and you will be asked to cycle the key "ON" and "OFF" a few times. Please keep the key position in the "OFF" position through the key cycles. 7. Screen will show "The diagnostic tester is unable to communicate with this vehicle." You will be prompted to "select a vehicle from the vehicle list", press TICK. 8. A list of vehicles will be displayed, select ALL OTHERS, and press TICK. 9. Screen shows "To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration number (7 digits), Tear Tag number (4 digits), or PCM part number, press TICK. 10. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 11. Follow and answer correctly all remaining screens. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) per Workshop Manual, Section 419-01. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 3115 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9F715 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine Controls/A/T - Unstable Idle/Shuddering TSB 06-11-7 06/12/06 2001-2005 ESCAPE 3.0L UNSTABLE IDLE - 2001-2003 ESCAPE 3.0L AUTOMATIC TRANSAXLE SHUDDER - MEXICO ONLY FORD: 2001-2005 Escape ISSUE Some 2001-2005 Escape vehicles equipped with a 3.0L engine may exhibit idle speeds outside the specified range. Some 2001-2003 Escape vehicles equipped with a 3.0L engine and CD4E automatic transaxle may exhibit a transmission shudder. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. If the concern is a 2001-2005 Escape with idle speeds outside the specified range: a. Install a new idle air control (IAC) valve with jumper harness included in the kit. The new Denso brand IAC will be installed with the electrical connector facing the opposite direction of the original (Hitachi) valve which is why the jumper harness is required. The original (Hitachi) IAC connector faces the front of the vehicle while the new Denso IAC connector faces toward the rear of the vehicle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 3121 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 3122 b. Referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the powertrain control module (PCM) using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 2. If the concern is a 2001 - 2003 Escape with transaxle shudder, drain, flush and refill the transmission fluid with MERCON(R) Multi-Purpose Automatic Transmission Fluid. Then, referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the PCM using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 3. When reprogramming the PCM use blank path programming. Select the proper file from the chart and manually enter the PCM part number or tear tag number to obtain the updated calibration file. To Perform Blank Path Programming: 1. Connect WDS/IDS to vehicle. 2. Select "16 pin", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 5. 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. 6. Screen shows to turn ignition ON. Keep ignition in the "OFF" position, press TICK and you will be asked to cycle the key "ON" and "OFF" a few times. Please keep the key position in the "OFF" position through the key cycles. 7. Screen will show "The diagnostic tester is unable to communicate with this vehicle." You will be prompted to "select a vehicle from the vehicle list", press TICK. 8. A list of vehicles will be displayed, select ALL OTHERS, and press TICK. 9. Screen shows "To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration number (7 digits), Tear Tag number (4 digits), or PCM part number, press TICK. 10. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 11. Follow and answer correctly all remaining screens. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) per Workshop Manual, Section 419-01. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 3123 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9F715 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Brake Pedal Position Switch Brake Signal: Description and Operation Brake Pedal Position Switch Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Brake Pedal Position Switch > Page 3129 Brake Signal: Description and Operation Brake Pressure Applied Brake Deactivator Switch Brake Pressure Applied Brake Deactivator Switch The Brake Pressure Applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, witch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3133 Camshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 3136 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 3137 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation Clutch Pedal Position Switch Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation > Page 3141 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3145 Coolant Temperature Sensor/Switch (For Computer): Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3146 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3147 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Partially drain the cooling system. 2. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the electrical connector. 2 Unclip and remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3151 Crankshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor 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 powertrain control module (PCM). The trigger 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 trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 25). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 3154 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3155 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the bolts and the right front lower splash shield. 3. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations View 151-17 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3161 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3162 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3163 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3164 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3165 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3166 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3167 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3168 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3169 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3170 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3171 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3172 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3173 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3174 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3175 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3176 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3177 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3178 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3179 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3180 Diagram 14-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Powertrain 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3185 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3186 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3187 View 151-11 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3188 Powertrain Control Module: Diagrams Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3189 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3190 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3191 Powertrain Control Module: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams > Page 3195 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. See: Description and Operation/Powertrain Control Software Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pump Signal > Component Information > Description and Operation Fuel Pump Signal: Description and Operation Fuel Pump Monitor Applications Using a Fuel Pump Relay for Fuel Pump On/Off Control The Fuel Pump Monitor (FPM) circuit is spliced into the Fuel Pump Power (FP PWR) circuit and is used by the PCM for diagnostic purposes. The PCM sources a low current voltage down the FPM circuit. With the fuel pump off, this voltage is pulled low by the path to ground through the fuel pump. With the fuel pump off and the FPM circuit low, the PCM can verify that the FPM circuit and the FP PWR circuit are complete from the FPM splice through the fuel pump to ground. This also confirms that the FP PWR or FPM circuits are not shorted to power. With the fuel pump on, voltage is now being supplied from the fuel pump relay to the FP PWR and FPM circuits. With the fuel pump on and the FPM circuit high, the PCM can verify that the FP PWR circuit from the fuel pump relay to the FPM splice is complete. It can also verify that the fuel pump relay contacts are closed and there is a B+ supply to the fuel pump relay Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3202 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline fuel tank pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3203 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3204 ^ Carry out a leak test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/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/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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation Idle Air Control Valve: 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 117) and (Figure 118) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation > Page 3208 Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors On applications with air-assisted injectors, the AC valve (Figure 119) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation > Page 3209 Idle Air Control Valve: Service and Repair REMOVAL 1. Remove the Idle Air Control (IAC) valve. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the valve. ^ Discard the gasket. INSTALLATION 1. To install, reverse the removal procedure. ^ Install a new gasket. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Specifications Module Communication Network: Specifications 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions Module Communication Network: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3215 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3216 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3217 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3218 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3219 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3220 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3221 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3222 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3223 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3224 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3225 Module Communication Network: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3226 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3227 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3228 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3229 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3230 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3231 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3232 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3233 Diagram 14-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation Module Communication Network: Description and Operation 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) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3236 Module Communication Network: Description and Operation Principles and 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3237 Module Communication Network: Description and Operation 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 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3238 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. See: Testing and Inspection/Module Configuration/Scan Tool Testing/Module Configuration Index 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network Module Communication Network: Testing and Inspection Module Communications Network Initial Inspection 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) Fuse ROOM (10 A) ^ 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 does not communicate with the vehicle, go to Pinpoint Test H. See: Pinpoint Tests/Pinpoint Tests/Test H: No Module/Network Communication 4. Go to Pinpoint Test PC. See: Pinpoint Tests/Pinpoint Test PC (Precheck) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3241 PC1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3242 A1 - A3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3243 A3 B1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3244 B2 - B3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3245 C1 - C3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3246 C3 Test D: IC Module Does Not Respond to the Diagnostic Tool D1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3247 D2 - D3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3248 D3 Test E: PCM Does Not Respond to the Diagnostic Tool E1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3249 E2 - E3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3250 E3 Test F: No Module/Network Communication - ISO 9141 Network F1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3251 F2 - F3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3252 F4 - F5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3253 F6 - F7 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3254 F8 - F10 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3255 F10 - F11 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3256 F12 Test G: No Module/Network Communication-SCP Network G1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3257 G2 - G3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3258 G4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3259 G5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3260 G6 - G7 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3261 G7 - G8 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3262 H1 - H3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3263 H4 Symptom Chart Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3264 Module Communication Network: Testing and Inspection Module Configuration Initial Inspection 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3265 Diagnostic Tool Message Index, Part 1 Diagnostic Tool Message Index, Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3266 A1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3267 A2 - A4 Symptom Chart Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Service and Repair > Module Communications Network Module Communication Network: Service and Repair Module Communications Network Communication Circuit Wiring Repair Heat Gun SPECIAL TOOL(S) 1. Disconnect the battery ground cable. 2. Strip the wires. 3. Solder the wires. 1 Install the heat shrink tube. 2 Twist the wires together. 3 Solder the wires together. NOTE: Use Rosin Core Mildly Activated (RMA) solder, not acid core solder. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Service and Repair > Module Communications Network > Page 3270 4. Bend the wires back in a straight line. NOTE: Wait for the solder to cool before moving the wires. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Service and Repair > Module Communications Network > Page 3271 Module Communication Network: Service and Repair Module Configuration 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 form the diagnostic tool for module reprogramming. 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. See: Testing and Inspection/Module Configuration/Scan Tool Testing/Module Configuration Index 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. See: Testing and Inspection/Module Configuration/Scan Tool Testing/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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment Module Communication Network: Tools and Equipment Special Tool(s) Heat Gun Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment > Page 3274 Module Communication Network: Tools and Equipment Diagnostic Special Service Tool(S) Special Tool(s) Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3278 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3279 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3280 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the bolt and the KS. NOTE: The KS is located on the RH side of the cylinder block INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3284 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3285 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3286 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3287 Powertrain Control Module Power Relay: Testing and Inspection Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3288 Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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) Check Engine, Service Engine Soon Or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control Module (PCM) has detected an On Board Diagnostic (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 16). ^ 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. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Reading Diagnostic Trouble Codes/Performance Diagnostic Procedures/Quick Test ^ 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature Engine Oil Temperature (EOT) Sensor The Engine Oil Temperature (EOT) sensor (Figure 29) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the engine coolant temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3300 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3301 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3302 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3303 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3304 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3305 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3306 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3307 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3308 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3309 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3310 Heated 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3311 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3312 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3313 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3314 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3315 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3316 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3317 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3318 Heated Oxygen Sensor: Connector Views Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3319 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3320 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input Heated Oxygen Sensor: Description and Operation PCM Input Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 32) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input > Page 3323 Heated Oxygen Sensor: Description and Operation Upstream Heated and Downstream Heated Oxygen Sensors Upstream Heated and Downstream Heated Oxygen Sensors 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.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH Heated Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) LH EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Raise and support the vehicle. 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH > Page 3326 Heated Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) RH EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 2. Raise and support the vehicle. 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH > Page 3327 Heated Oxygen Sensor: Service and Repair Catalyst Monitor Sensor LH EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Raise and support the vehicle. 2. Disconnect the catalyst monitor sensor electrical connector. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH > Page 3328 Heated Oxygen Sensor: Service and Repair Catalyst Monitor Sensor RH 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Signal > Component Information > Description and Operation Power Steering Pressure Signal: Description and Operation Power Steering Pressure Sensor Power Steering Pressure (PSP) Sensor The power steering pressure (PSP) sensor (Figure 38) monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM will change as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams Power Steering Pressure Switch: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Page 3335 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Power Steering Pressure (PSP) Switch The Power Steering Pressure (PSP) switch (Figure 37) monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Page 3336 Power Steering Pressure Switch: Service and Repair REMOVAL 1. Remove the Power Steering Pressure (PSP) switch. 1 Disconnect the electrical connector. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3345 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3346 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3347 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3348 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3349 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3355 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3356 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3357 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3358 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3359 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3364 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3365 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3366 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3372 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3373 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3374 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3375 View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3376 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3377 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) 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 aluminum 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3378 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3379 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Powertrain 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3385 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3386 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3387 View 151-11 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3388 Powertrain Control Module: Diagrams Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3389 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3390 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3391 Powertrain Control Module: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3395 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3396 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3397 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3398 Powertrain Control Module Power Relay: Testing and Inspection Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3399 Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation Thermal Manifold Absolute Pressure Sensor Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 40) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3407 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3408 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3409 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3410 Mass Air Flow 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3414 Camshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 3417 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 3418 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation Clutch Pedal Position Switch Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation > Page 3422 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3426 Coolant Temperature Sensor/Switch (For Computer): Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3427 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3428 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Partially drain the cooling system. 2. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the electrical connector. 2 Unclip and remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3432 Crankshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor 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 powertrain control module (PCM). The trigger 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 trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 25). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 3435 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3436 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the bolts and the right front lower splash shield. 3. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams > Page 3440 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. See: Description and Operation/Powertrain Control Software Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3444 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline fuel tank pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3445 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3446 ^ Carry out a leak test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/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/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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors (Figure 33) and integrated Mass Air Flow (MAF) type (Figure 36), are thermistor devices in which resistance changes with temperature The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged vehicles use (2) IAT sensors. Both sensors are thermistor type devices and operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Currently two types of IAT2 sensors are used. A screw in type (Figure 33) and an integrated type, witch is part of the Thermal Manifold Absolute Pressure (TMAP) sensor (Figure 40). The TMAP sensor consists of a IAT thermistor and a Manifold Absolute Pressure (MAP) sensor. The thermistor portion of the TMAP is used for IAT2 function and operates in the same manner as a non-integrated IAT2. For additional information on the MAP portion of the TMAP, refer to the Thermal Manifold Absolute Pressure Sensor description and operation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3453 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3454 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3455 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the bolt and the KS. NOTE: The KS is located on the RH side of the cylinder block INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature Engine Oil Temperature (EOT) Sensor The Engine Oil Temperature (EOT) sensor (Figure 29) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the engine coolant temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3464 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3465 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3466 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3467 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3468 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3469 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3470 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3471 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3472 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3473 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3474 Heated 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3475 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3476 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3477 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3478 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3479 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3480 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3481 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3482 Heated Oxygen Sensor: Connector Views Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3483 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3484 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input Heated Oxygen Sensor: Description and Operation PCM Input Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 32) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input > Page 3487 Heated Oxygen Sensor: Description and Operation Upstream Heated and Downstream Heated Oxygen Sensors Upstream Heated and Downstream Heated Oxygen Sensors 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.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH Heated Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) LH EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Raise and support the vehicle. 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH > Page 3490 Heated Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) RH EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 2. Raise and support the vehicle. 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH > Page 3491 Heated Oxygen Sensor: Service and Repair Catalyst Monitor Sensor LH EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Raise and support the vehicle. 2. Disconnect the catalyst monitor sensor electrical connector. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) LH > Page 3492 Heated Oxygen Sensor: Service and Repair Catalyst Monitor Sensor RH 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams Power Steering Pressure Switch: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Page 3496 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Power Steering Pressure (PSP) Switch The Power Steering Pressure (PSP) switch (Figure 37) monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Page 3497 Power Steering Pressure Switch: Service and Repair REMOVAL 1. Remove the Power Steering Pressure (PSP) switch. 1 Disconnect the electrical connector. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3506 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3507 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3508 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3509 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3510 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3516 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3517 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3518 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3519 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3520 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3525 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3526 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3527 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3533 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3534 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3535 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3536 View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3537 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3538 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) 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 aluminum 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3539 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3540 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3544 Throttle Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3545 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3546 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the nuts and the engine appearance cover. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the sensor NOTE: Air cleaner outlet tube is removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Torque Specifications Transmission range (TR) sensor bolts ................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3550 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3551 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3552 Digital Transmission Range 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3553 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3554 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3555 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input Vehicle Speed Sensor: Description and Operation PCM Input Vehicle Speed Sensor Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 44) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input > Page 3561 Vehicle Speed Sensor: Description and Operation PCM Output Powertrain Control Module - Vehicle Speed Output (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH ( 1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3565 Throttle Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3566 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3567 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the nuts and the engine appearance cover. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the sensor NOTE: Air cleaner outlet tube is removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Torque Specifications Transmission range (TR) sensor bolts ................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3571 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3572 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3573 Digital Transmission Range 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3574 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3575 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3576 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Cam Timing System Variable Valve Timing Solenoid: Description and Operation Variable Cam Timing System Overview The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the combustion chamber. The residual gases cool the combustion chamber and are inert when mixed with the incoming fresh charge of fuel and air. This results in better fuel economy and lower Nitrogen Oxides (NOx) and Hydrocarbons (HC) the engine produces. The Exhaust Gas Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature. Variable Cam Timing Variable Cam Timing System The Variable Cam Timing (VCT) System consists of the control solenoid, five-tooth pulse ring (4+1) on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP) sensor, Powertrain Control Module (PCM) (Figure 127). 1. The powertrain control module (PCM) receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, camshaft position (CMP) sensor, mass air flow (MAF) sensor and crankshaft position (CKP) sensor for determining the operating conditions of the engine. 2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are met. The PCM disables the VCT system if a fault is detected. 3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse ring mounted on the exhaust camshaft. Relative cam position is calculated by measuring the time between the rising edge of Profile Ignition Pickup (PIP) and the falling edge of VCT pulse. 4. The PCM continually calculates a cam position error value based on the difference between the desired and actual position and a duty cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit. 5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a rotation motion from the helical mechanism in the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve to correct for cam position error. Hardware Variable Cam Timing (VCT) Solenoid Valve Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Cam Timing System > Page 3581 Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 128) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 129) 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, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion 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. The camshaft is allowed to rotate up to 30 degrees. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Cam Timing System > Page 3582 Variable Valve Timing Solenoid: Description and Operation Variable Cam Timing (Vct) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 128) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Cam Timing System > Page 3583 Variable Valve Timing Solenoid: Description and Operation Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 129) 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, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion 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. The camshaft is allowed to rotate up to 30 degrees. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input Vehicle Speed Sensor: Description and Operation PCM Input Vehicle Speed Sensor Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 44) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input > Page 3589 Vehicle Speed Sensor: Description and Operation PCM Output Powertrain Control Module - Vehicle Speed Output (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH ( 1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid > Component Information > Description and Operation Air Diverter Solenoid: Description and Operation AIR Bypass Solenoid Secondary Air Injection Bypass Solenoid The secondary Air Injection Bypass (AIR bypass) solenoid (Figure 122) 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation Air Diverter Valve: Description and Operation AIR Diverter Valve Air Injection Diverter (AIR Diverter) Valve The secondary Air Injection Diverter (AIR diverter) valve (Figure 123) 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Description and Operation Air Injection Pump: Description and Operation Electric AIR Pump Electric Air Pump The electric AIR pump (Figure 121) 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation Solid State Relay Solid State Relay The solid state relay (Figure 124) 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). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve, AIR > Component Information > Description and Operation Vacuum Check Valve: Description and Operation Vacuum Check Valves Vacuum Check Valve A vacuum check valve (Figure 125) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Catalyst and Exhaust Systems Catalytic Converter: Description and Operation Catalyst and Exhaust Systems Overview Generic Catalyst And Exhaust System The Catalytic Converter and Exhaust Systems (Figure 133) 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 (CO2) 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, upstream Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD II) system. (Refer to OBD II Monitors to Catalyst Efficiency Monitor-Federal Test Procedure for specific information.) 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. TWC Conversion Efficiency Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Catalyst and Exhaust Systems > Page 3611 TWC Conversion Efficiency Chart 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. Devations outside of this window will greatly decrease the conversion efficiency (Figure 134). For example a rich mixture will decrease the HC and CO conversion efficiency while a lean mixture will decreases the NOx conversion efficiency. 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 and than on in the muffler. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. Hardware The downstream HO2S may be located after the light off catalyst or underbody 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, refer to 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 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. Upstream Heated and Downstream Heated Oxygen Sensors 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.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Catalyst and Exhaust Systems > Page 3612 atmosphere. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Catalyst and Exhaust Systems > Page 3613 Catalytic Converter: Description and Operation Catalytic Converter 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3614 Catalytic Converter: Service and Repair Catalytic Converter-3.0L (4V) Removal and Installation 1. Raise and support the vehicle. 2. Remove and discard the nuts. ^ Discard the gasket. 3. Remove the U-bolt, disconnect the catalytic converter from the hanger. 4. Remove and discard the nuts between main silencer and after silencer pipe. 5. Remove converter and main silencer together. 6. Remove converter from main silencer on the floor. 7. To install, reverse the removal procedure. ^ Install a new gasket. ^ Install new nuts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3619 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3620 Canister Purge Control Valve: Description and Operation EVAP Canister Purge Valve EVAP Canister Purge Valve EVAP Canister Purge Valve The EVAP canister purge valve (Figure 95) and (Figure 96) is the 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3621 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/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service Precautions > Page 3625 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service Precautions > Page 3626 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/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Service Precautions Evaporative Check 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Service Precautions > Page 3630 Evaporative Check 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Service Precautions > Page 3631 6. Remove the evaporative emission check valve. INSTALLATION 1. To install, reverse the removal procedure. ^ Carry out a leak test. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission Repair Verification Drive Cycle NOTE: Lubricate all O-ring seals with MERPOL® O-Ring Seal Lubricant meeting Ford specification ESE-M99B144-B or equivalent. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service Precautions > Page 3635 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service Precautions > Page 3636 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/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service Precautions Evaporative Emissions Hose: Service Precautions 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service Precautions > Page 3640 Evaporative Emissions Hose: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams > Page 3644 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams > Page 3645 Leak Detection Valve: Description and Operation Canister Vent Solenoid Typical Canister Vent (CV) Solenoid During the Enhanced EVAP System test monitor, the Canister Vent (CV) solenoid (Figure 99) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams > Page 3646 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams > Page 3647 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/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation > Page 3651 On-Board Refueling Vapor Recovery Evaporative Emission System The basic elements forming the ORVR system (Figure 101), (Figure 102) and (Figure 103) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Diagrams > Page 3656 EGR Electronic Vacuum Regulator Solenoid: Description and Operation EGR Vacuum Regulator Solenoid EGR Vacuum Regulator Solenoid Test Graph EGR Vacuum Regulator Solenoid Data Chart The EGR vacuum regulator solenoid (Figure 88) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Diagrams > Page 3657 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 PCM wiring harness bracket. ^ Remove the nut. ^ Position the bracket aside. 4. Remove the bolts and remove the EGR vacuum regulator valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service Precautions > Page 3661 EGR Tube: Description and Operation Orifice Tube Assembly Orifice Tube Assembly The orifice tube assembly (Figure 90) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service Precautions > Page 3662 EGR Tube: Service and Repair REMOVAL 1. Disconnect the EGR tube nut at the manifold connector. 2. Carefully remove the differential pressure feedback EGR sensor from the EGR tube. 3. Disconnect the EGR tube fitting and remove the EGR tube. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Differential Pressure Feedback EGR System EGR Valve: Description and Operation Differential Pressure Feedback EGR System Exhaust Gas Recirculation Valve EGR Valve Test Graph The EGR valve (Figure 89) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Differential Pressure Feedback EGR System > Page 3668 EGR Valve: Description and Operation Electric Motor EGR System (EEGR) Electric Motor EGR System (EEGR) Highlights of the Electric System ^ EEGR valve is activated by an electric stepper motor not a vacuum motor (Rear of engine block). ^ No vacuum diaphragm is used. ^ No DPFE sensor is used. ^ No Orifice Tube/Assembly is used. ^ No EGR vacuum regulator solenoid is used. ^ A new Manifold Absolute Pressure (MAP) sensor is used (called Thermal Manifold Absolute Pressure (TMAP) but the temperature function is not used at this time) (located on top of the valve cover). ^ Engine coolant is routed through the assembly extending durability of the electric motor. Overview Electric EGR System The electric EGR system uses exhaust gas recirculation to control the Oxides Of Nitrogen (NOx) emissions just like vacuum operated systems. The only difference is the way in which the exhaust gas is controlled. The Electric EGR system consists of an electric motor/EGR valve integrated assembly, a PCM, and connecting wiring. Additionally a MAP sensor is also required. Operation of the system is as follows (Figure 91): 1. The EEGR system receives signals from the Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, crankshaft position (CKP) sensor and the manifold absolute pressure (MAP) sensor to provide information on engine operating conditions to the PCM. The engine must be warm, stable and running at a moderate load and rpm before the EEGR system is activated. The PCM will deactivate EGR during idle, extended wide open throttle or whenever a failure is detected in an EEGR component or EGR required input. 2. The PCM calculates the desired amount of EGR for a given set of engine operating conditions. 3. The PCM in turn will output signals to the EEGR motor to move (advance or retract) a certain number of discrete steps. The electric stepper motor will directly actuate the EGR valve, independent of engine vacuum. The EGR valve is commanded from 0 to 52 discrete increments or "steps" to get the EGR valve from a fully closed to full or partially open position. The position of the EGR valve determines the EGR flow. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Differential Pressure Feedback EGR System > Page 3669 4. A MAP sensor is used to measure variations in manifold pressure as exhaust gas recirculation is introduced into the intake manifold. Variations in EGR being used will correlate to the MAP signal (increasing EGR will increase manifold pressure values). Hardware Electric EGR Motor/Valve Assembly Electric EGR The electric EGR valve (Figure 92) and (Figure 93) is a water cooled motor/valve assembly. The motor is commanded to move in 52 discrete steps as it acts directly on the the EGR valve. The position of the valve determines the rate of EGR. The built in spring works to close the valve (against Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Differential Pressure Feedback EGR System > Page 3670 the motor opening force). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 3671 EGR Valve: Service and Repair REMOVAL 1. Remove the EGR valve. 1 Disconnect the vacuum line. 2 Disconnect the EGR tube. 3 Remove the EGR valve and discard the gasket. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3680 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3681 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3682 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3683 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3684 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3690 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3691 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3692 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3693 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3694 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3699 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3700 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3701 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3707 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3708 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3709 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3710 View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3711 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3712 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) 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 aluminum 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3713 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3714 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation Positive Crankcase Ventilation: Description and Operation Overview PCV System The Positive Crankcase Ventilation (PCV) System (Figure 130) cycles crankcase gases back through the engine where they are burned. The PCV valve regulates the amount of ventilating air and blow-by gas to the intake manifold and prevents backfire from traveling into the crankcase. The PCV valve should be mounted in a vertical position. On some applications, the PCV system is connected to the evaporative emission system (refer to the VECI decal). CAUTION: Do not remove the PCV system from the engine. Removal of the PCV system will adversely affect the fuel economy and engine ventilation and result in shorter engine life. Hardware PCV Internal Drawing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 3718 Typical PCV Vacuum Connector Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation Solid State Relay Solid State Relay The solid state relay (Figure 124) 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). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3732 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3733 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3734 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3735 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3736 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3742 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3743 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION 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 SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3744 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3745 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3746 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3751 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3752 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3753 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3759 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3760 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3761 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3762 View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3763 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3764 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) 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 aluminum 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3765 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3766 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions Fuel Pressure Test Port: 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. ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3772 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3773 Fuel Pressure Test Port: 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 pressure. 2. Remove the pressure relief valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 3777 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) 1. Remove the Schrader valve cap at the end of the fuel injection supply manifold and attach the Fuel Pressure Gauge. 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. Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. NOTE: Position a suitable container for the fuel to drain into. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 3778 Fuel Pressure Gauge Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 730 - 750 RPM Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Torque Specifications Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service Precautions > Technician Safety Information > Page 3787 Accelerator Pedal: Vehicle Damage Warnings CAUTION: Do not pull the accelerator cable out by the cable housing. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service Precautions > Page 3788 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3791 Symptom Chart Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 crankcase ventilation hose. 2. Remove the bolt, the nuts and the engine appearance cover. 3. Disconnect the accelerator cable from the throttle lever. 1 Rotate the throttle lever. 2 Slide the accelerator cable end out of the throttle lever. 4. Remove the accelerator pedal and shaft assembly. 1 Disconnect the accelerator cable. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal and Shaft > Page 3794 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal and Shaft > Page 3795 Accelerator Pedal: Service and Repair Cable REMOVAL 1. Disconnect the crankcase ventilation hose. 2. Remove the bolt, the nuts and the engine appearance cover. 3. Disconnect the accelerator cable from the bracket. 1 Rotate the throttle lever. 2 Slide the accelerator cable end out of the throttle lever. 3 Disconnect the accelerator cable from the bracket. 4. Disconnect the accelerator cable from the pedal. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal and Shaft > Page 3796 5. Remove the accelerator cable. CAUTION: Do not pull the accelerator cable out by the cable housing. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal and Shaft > Page 3797 Accelerator Pedal: Service and Repair Cable Bracket REMOVAL 1. Disconnect the crankcase ventilation hose. 2. Remove the bolt, nuts and the engine appearance cover. 3. Disconnect the throttle control linkage from the throttle lever. 1 If equipped, disconnect the speed control cable from the throttle lever. 2 Rotate the throttle lever. 3 Slide the accelerator cable end out of the throttle lever. 4. Disconnect the throttle control linkage from the accelerator cable bracket. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal and Shaft > Page 3798 1 Disconnect the accelerator cable from the bracket. 2 If equipped, squeeze the tabs and disconnect the speed control cable from the accelerator cable bracket. 5. Remove the bolts and the accelerator cable bracket. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3806 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3807 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3808 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3809 Mass Air Flow 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering Auxiliary Air Valve (Idle Speed): Customer Interest Engine Controls/A/T - Unstable Idle/Shuddering TSB 06-11-7 06/12/06 2001-2005 ESCAPE 3.0L UNSTABLE IDLE - 2001-2003 ESCAPE 3.0L AUTOMATIC TRANSAXLE SHUDDER - MEXICO ONLY FORD: 2001-2005 Escape ISSUE Some 2001-2005 Escape vehicles equipped with a 3.0L engine may exhibit idle speeds outside the specified range. Some 2001-2003 Escape vehicles equipped with a 3.0L engine and CD4E automatic transaxle may exhibit a transmission shudder. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. If the concern is a 2001-2005 Escape with idle speeds outside the specified range: a. Install a new idle air control (IAC) valve with jumper harness included in the kit. The new Denso brand IAC will be installed with the electrical connector facing the opposite direction of the original (Hitachi) valve which is why the jumper harness is required. The original (Hitachi) IAC connector faces the front of the vehicle while the new Denso IAC connector faces toward the rear of the vehicle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 3818 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 3819 b. Referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the powertrain control module (PCM) using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 2. If the concern is a 2001 - 2003 Escape with transaxle shudder, drain, flush and refill the transmission fluid with MERCON(R) Multi-Purpose Automatic Transmission Fluid. Then, referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the PCM using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 3. When reprogramming the PCM use blank path programming. Select the proper file from the chart and manually enter the PCM part number or tear tag number to obtain the updated calibration file. To Perform Blank Path Programming: 1. Connect WDS/IDS to vehicle. 2. Select "16 pin", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 5. 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. 6. Screen shows to turn ignition ON. Keep ignition in the "OFF" position, press TICK and you will be asked to cycle the key "ON" and "OFF" a few times. Please keep the key position in the "OFF" position through the key cycles. 7. Screen will show "The diagnostic tester is unable to communicate with this vehicle." You will be prompted to "select a vehicle from the vehicle list", press TICK. 8. A list of vehicles will be displayed, select ALL OTHERS, and press TICK. 9. Screen shows "To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration number (7 digits), Tear Tag number (4 digits), or PCM part number, press TICK. 10. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 11. Follow and answer correctly all remaining screens. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) per Workshop Manual, Section 419-01. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 3820 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9F715 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine Controls/A/T - Unstable Idle/Shuddering TSB 06-11-7 06/12/06 2001-2005 ESCAPE 3.0L UNSTABLE IDLE - 2001-2003 ESCAPE 3.0L AUTOMATIC TRANSAXLE SHUDDER - MEXICO ONLY FORD: 2001-2005 Escape ISSUE Some 2001-2005 Escape vehicles equipped with a 3.0L engine may exhibit idle speeds outside the specified range. Some 2001-2003 Escape vehicles equipped with a 3.0L engine and CD4E automatic transaxle may exhibit a transmission shudder. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. If the concern is a 2001-2005 Escape with idle speeds outside the specified range: a. Install a new idle air control (IAC) valve with jumper harness included in the kit. The new Denso brand IAC will be installed with the electrical connector facing the opposite direction of the original (Hitachi) valve which is why the jumper harness is required. The original (Hitachi) IAC connector faces the front of the vehicle while the new Denso IAC connector faces toward the rear of the vehicle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 3826 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 3827 b. Referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the powertrain control module (PCM) using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 2. If the concern is a 2001 - 2003 Escape with transaxle shudder, drain, flush and refill the transmission fluid with MERCON(R) Multi-Purpose Automatic Transmission Fluid. Then, referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the PCM using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 3. When reprogramming the PCM use blank path programming. Select the proper file from the chart and manually enter the PCM part number or tear tag number to obtain the updated calibration file. To Perform Blank Path Programming: 1. Connect WDS/IDS to vehicle. 2. Select "16 pin", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 5. 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. 6. Screen shows to turn ignition ON. Keep ignition in the "OFF" position, press TICK and you will be asked to cycle the key "ON" and "OFF" a few times. Please keep the key position in the "OFF" position through the key cycles. 7. Screen will show "The diagnostic tester is unable to communicate with this vehicle." You will be prompted to "select a vehicle from the vehicle list", press TICK. 8. A list of vehicles will be displayed, select ALL OTHERS, and press TICK. 9. Screen shows "To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration number (7 digits), Tear Tag number (4 digits), or PCM part number, press TICK. 10. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 11. Follow and answer correctly all remaining screens. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) per Workshop Manual, Section 419-01. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 3828 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9F715 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3837 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3838 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3839 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3840 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3841 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3847 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3848 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3849 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3850 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3851 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 3852 Fuel Filler Cap: Description and Operation Fuel Filler Cap Fuel Filler Cap The fuel filler cap (Figure 100) is used to prevent fuel spill and close the evaporative emission/fuel system to atmosphere. Some vehicles may have a Fuel Cap Off 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3857 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) 1. Remove the Schrader valve cap at the end of the fuel injection supply manifold and attach the Fuel Pressure Gauge. 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. Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. NOTE: Position a suitable container for the fuel to drain into. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3858 Fuel Pressure Gauge Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 3863 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 upper intake manifold. 2. Disconnect the coil-on-plug electrical connectors. 3. Disconnect the radio ignition noise suppressor electrical connector. 4. Remove the Engine Coolant Temperature (ECT) sensor electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 3864 5. Disconnect the 16-pin electrical connectors. 6. Disconnect Power Steering Pressure (PSP) switch electrical connector. 7. Disconnect the six fuel injector electrical connectors and release the wiring harness locators from the fuel injection supply manifold. NOTE: One connector is shown, the other five connectors are similar. 8. Disconnect the Camshaft Position (CMP) sensor electrical connector. 9. Remove the RH wheel and tire assembly. 10. Remove the RH lower splash shield. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 3865 11. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 12. Disconnect the oil pressure sensor electrical connector. NOTE: The oil pressure sensor is located behind the rear of the A/C compressor. The A/C compressor has been removed for clarity. 13. Lower the vehicle. 14. Remove the fuel charging wiring harness from the vehicle. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Technician Safety Information > Page 3870 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 3873 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 3874 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 3875 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 3876 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 3877 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3878 Fuel Pipe 1/2 Inch Remover (Green) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator Fuel Pressure Regulator The fuel pressure regulator (Figure 70) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations View 151-27 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3885 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3886 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 30) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor 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. Fuel Rail Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 31) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions Fuel Pressure Test Port: 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. ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3890 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3891 Fuel Pressure Test Port: 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 pressure. 2. Remove the pressure relief valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Technician Safety Information > Page 3896 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Page 3897 Fuel Pressure Pulsation Damper: Description and Operation Fuel Rail Pulse Damper Pulse Damper The fuel rail pulse damper (Figure 71) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Page 3898 Fuel Pressure Pulsation Damper: Service and Repair REMOVAL 1. Remove the throttle body. 2. Remove the fuel pulse damper. 1 Disconnect the vacuum hose. 2 Remove the snap ring. 3 Remove the damper. 3. Remove and discard the O-ring seal. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use an O-ring seal that is made of special fuel resistant material. Use of an ordinary O-ring seal can cause the fuel system to leak. Do not reuse the O-ring seal. NOTE: Lubricate the O-ring seal with clean engine oil. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions Fuel Pressure Test Port: 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. ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3904 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3905 Fuel Pressure Test Port: 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 pressure. 2. Remove the pressure relief valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation Fuel Pump Driver Module Applications Fuel Pump Driver Module Duty Cycle Signals The Fuel Pump Driver Module (FPDM) communicates diagnostic information to the powertrain control module (PCM) through the Fuel Pump Monitor (FPM) circuit. This information is sent by the FPDM as a duty cycle signal. The three duty cycle signals that may be sent are listed in the table. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3912 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3913 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3914 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3915 Fuel Pump Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3916 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Technician Safety Information > Page 3921 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 3922 Fuel Rail: 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. Remove the upper intake manifold. 2. Disconnect the fuel line. 3. Disconnect the six fuel injector electrical connectors and release the wiring harness locators from the fuel injection supply manifold. NOTE: One connector is shown, the other five connectors are similar. 4. Remove the fuel injection supply manifold. ^ Remove the vacuum hose. ^ Remove the bolts and the manifold. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Lubricate the fuel injector O-ring seals with clean engine oil to aid installation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3932 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3933 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3934 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3935 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3936 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3942 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3943 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3944 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3945 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3946 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 3947 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 3948 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 3949 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 3950 Heavy - Duty Riveter Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3959 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3960 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3961 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3962 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3963 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3969 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3970 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3971 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3972 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 3973 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor Engine Fuel Temperature (EFT) Sensor The Engine Fuel Temperature (EFT) sensor (Figure 28) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EFT sensor measures the temperature 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation Idle Air Control Valve: 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 117) and (Figure 118) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation > Page 3986 Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors On applications with air-assisted injectors, the AC valve (Figure 119) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation > Page 3987 Idle Air Control Valve: Service and Repair REMOVAL 1. Remove the Idle Air Control (IAC) valve. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the valve. ^ Discard the gasket. INSTALLATION 1. To install, reverse the removal procedure. ^ Install a new gasket. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-25 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3991 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3992 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3993 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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. Remove the air cleaner outlet pipe. 1 Disconnect the crankcase vent hose. 2 Loosen the screw clamps. INSTALLATION 2. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4000 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4001 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4002 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4003 Powertrain Control Module Power Relay: Testing and Inspection Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4004 Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation Fuel Pump Driver Module Applications Fuel Pump Driver Module Duty Cycle Signals The Fuel Pump Driver Module (FPDM) communicates diagnostic information to the powertrain control module (PCM) through the Fuel Pump Monitor (FPM) circuit. This information is sent by the FPDM as a duty cycle signal. The three duty cycle signals that may be sent are listed in the table. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4012 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4013 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4014 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4015 Fuel Pump Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4016 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4020 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4021 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4022 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4023 Powertrain Control Module Power Relay: Testing and Inspection Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4024 Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4032 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4033 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4034 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4035 Mass Air Flow 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4039 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4040 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 30) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor 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. Fuel Rail Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 31) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor Engine Fuel Temperature (EFT) Sensor The Engine Fuel Temperature (EFT) sensor (Figure 28) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EFT sensor measures the temperature 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4047 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4048 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4049 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 151-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4053 Throttle Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4054 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4055 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the nuts and the engine appearance cover. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the sensor NOTE: Air cleaner outlet tube is removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Throttle Body Bolt and Stud 89 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Technician Safety Information > Page 4061 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 4062 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 On-Board Diagnostic (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 AC 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 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. Typical 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 116) advising not to clean. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 4063 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 tube. 2. Remove the nuts and the engine appearance cover. 3. Disconnect the accelerator cable and the speed control cable (if equipped) from the throttle body lever. 4. Disconnect the Throttle Position (TP) sensor electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 4064 5. Remove the bolt, the stud bolt and the throttle body. ^ Discard the gasket. INSTALLATION 1. To install, reverse the removal procedure. ^ Install a new gasket. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Recalls for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall (LHD Vehicles) Throttle Cable Replacement Technical Service Bulletin # 04S25U Date: 051006 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Recalls for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall (LHD Vehicles) Throttle Cable Replacement > Page 4073 Attachment I - Administrative Information OASIS ACTIVATED? Yes OASIS was activated on December 07, 2004. FSA VIN LIST ACTIVATED? Yes Available through the website on December 09, 2004. Owner names and addresses were available on January 17, 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 affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be 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 (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. [New!] 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 Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Recalls for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall (LHD Vehicles) Throttle Cable Replacement > Page 4074 Note: Related damage claims will not be accepted for speed control cable replacement. Please review the revised technical instructions/illustrations found in Attachment III. 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. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition call the Special Service Support Center. 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 out the VIN for this recall. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 04S25 - 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). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. The DOR/COR for this program is 50336. This number identifies parts ordered for this recall through the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Recalls for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall (LHD Vehicles) Throttle Cable Replacement > Page 4075 DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." CLAIM HANDLING PROCEDURE FOR RETURNING PRIOR LEVEL ACCELERATOR CABLES Immediate Purge Required ------YL8Z-9A758-AD Accelerator Cable - 3.0L Prepare and submit a PCS claim as described below: ^ DO NOT ship the parts until Return Authorization is granted. ^ The return authorizations will include shipping addresses. PCS CLAIM INSTRUCTIONS When you create your PCS claim, use the following information for the REASON CODE, SHIPPER NBR, and LINE EXPLANATION fields: ^ REASON CODE: GB ^ SHIPPER NBR: 04S25 ^ 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 January 31, 2005. Claims filed after this date will be denied. 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 SERVICE PROCEDURE ACCELERATOR CABLE REMOVAL 1. From inside the vehicle, disconnect the accelerator cable from the pedal. 2. Remove the engine appearance cover, if equipped. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Recalls for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall (LHD Vehicles) Throttle Cable Replacement > Page 4076 [NEW] CAUTION: Damage to the speed control cable may result if the throttle body cam is rotated by lifting upon the speed control cable or the speed control cable connector end. When disconnecting the accelerator cable from the throttle body, rotate the throttle body cam only by lifting upon the cam itself. See Figure 1. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Recalls for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall (LHD Vehicles) Throttle Cable Replacement > Page 4077 3. Disconnect the accelerator cable as follows: See Figure 2. A) Disconnect the cable by rotating the throttle body cam and sliding the cable barrel out of the cam. B) Remove the accelerator cable from bracket # 1 by turning the cable housing 45 degrees either way and pulling it from the bracket. C) Open bracket # 2 with a screwdriver and remove the accelerator cable from the bracket. See Figure 3. D) Detach the accelerator cable from the clip located on the brake booster vacuum hose. E) Disengage the grommet at the dash panel and remove the accelerator cable from the vehicle. ACCELERATOR CABLE INSTALLATION 1. Feed the new cable through the dash panel and fully seat the grommet. 2. Install and connect the accelerator cable as follows: A) Connect the cable to the throttle body by rotating the cam and sliding the cable barrel into the cam. B) Attach the accelerator cable to the clip located on the brake booster vacuum hose. C) Secure the accelerator cable to bracket # 1 by inserting it and rotating the cable housing 45 degrees to lock it in place. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Recalls for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall (LHD Vehicles) Throttle Cable Replacement > Page 4078 D) Position the accelerator cable in bracket # 2 and, using a suitable tool, bend down the tab to retain the cable while ensuring the cable moves freely in the bracket. See Figure 4. 3. Connect the accelerator cable to the pedal. 4. Install the appearance cover, if equipped. 5. Check for free movement of the accelerator pedal and that there is no binding. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Recalls for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall (LHD Vehicles) Throttle Cable Replacement > Page 4079 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Recalls for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall (LHD Vehicles) Throttle Cable Replacement > Page 4080 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Recalls for Throttle Cable/Linkage: > NHTSA04V574000 > Dec > 04 > Recall 04V574000: Throttle Cable Replacement Throttle Cable/Linkage: Recalls Recall 04V574000: Throttle Cable Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Escape 2002-2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 04V574000 Recall Date: Dec 06, 2004 COMPONENT: Vehicle Speed Control: Cables POTENTIAL NUMBER OF UNITS AFFECTED: 470245 SUMMARY: On certain sport utility vehicles built with 3.0L V6 engines, the accelerator cable may prevent the throttle from returning to the idle position. CONSEQUENCE: An unexpected increase in engine idle speed may increase stopping distance and may result in a vehicle crash. REMEDY: Dealers will replace the accelerator cable. The recall is expected to begin on January 17, 2005. Owners should contact Ford at 1-866-436-7332. NOTES: Ford recall No. 04S25. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall - (LHD Vehicles) Throttle Cable Replacement Technical Service Bulletin # 04S25U Date: 051006 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall - (LHD Vehicles) Throttle Cable Replacement > Page 4090 Attachment I - Administrative Information OASIS ACTIVATED? Yes OASIS was activated on December 07, 2004. FSA VIN LIST ACTIVATED? Yes Available through the website on December 09, 2004. Owner names and addresses were available on January 17, 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 affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be 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 (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. [New!] 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 Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall - (LHD Vehicles) Throttle Cable Replacement > Page 4091 Note: Related damage claims will not be accepted for speed control cable replacement. Please review the revised technical instructions/illustrations found in Attachment III. 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. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition call the Special Service Support Center. 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 out the VIN for this recall. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 04S25 - 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). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. The DOR/COR for this program is 50336. This number identifies parts ordered for this recall through the Special Service Support Center. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall - (LHD Vehicles) Throttle Cable Replacement > Page 4092 DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." CLAIM HANDLING PROCEDURE FOR RETURNING PRIOR LEVEL ACCELERATOR CABLES Immediate Purge Required ------YL8Z-9A758-AD Accelerator Cable - 3.0L Prepare and submit a PCS claim as described below: ^ DO NOT ship the parts until Return Authorization is granted. ^ The return authorizations will include shipping addresses. PCS CLAIM INSTRUCTIONS When you create your PCS claim, use the following information for the REASON CODE, SHIPPER NBR, and LINE EXPLANATION fields: ^ REASON CODE: GB ^ SHIPPER NBR: 04S25 ^ 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 January 31, 2005. Claims filed after this date will be denied. 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 SERVICE PROCEDURE ACCELERATOR CABLE REMOVAL 1. From inside the vehicle, disconnect the accelerator cable from the pedal. 2. Remove the engine appearance cover, if equipped. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall - (LHD Vehicles) Throttle Cable Replacement > Page 4093 [NEW] CAUTION: Damage to the speed control cable may result if the throttle body cam is rotated by lifting upon the speed control cable or the speed control cable connector end. When disconnecting the accelerator cable from the throttle body, rotate the throttle body cam only by lifting upon the cam itself. See Figure 1. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall - (LHD Vehicles) Throttle Cable Replacement > Page 4094 3. Disconnect the accelerator cable as follows: See Figure 2. A) Disconnect the cable by rotating the throttle body cam and sliding the cable barrel out of the cam. B) Remove the accelerator cable from bracket # 1 by turning the cable housing 45 degrees either way and pulling it from the bracket. C) Open bracket # 2 with a screwdriver and remove the accelerator cable from the bracket. See Figure 3. D) Detach the accelerator cable from the clip located on the brake booster vacuum hose. E) Disengage the grommet at the dash panel and remove the accelerator cable from the vehicle. ACCELERATOR CABLE INSTALLATION 1. Feed the new cable through the dash panel and fully seat the grommet. 2. Install and connect the accelerator cable as follows: A) Connect the cable to the throttle body by rotating the cam and sliding the cable barrel into the cam. B) Attach the accelerator cable to the clip located on the brake booster vacuum hose. C) Secure the accelerator cable to bracket # 1 by inserting it and rotating the cable housing 45 degrees to lock it in place. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall - (LHD Vehicles) Throttle Cable Replacement > Page 4095 D) Position the accelerator cable in bracket # 2 and, using a suitable tool, bend down the tab to retain the cable while ensuring the cable moves freely in the bracket. See Figure 4. 3. Connect the accelerator cable to the pedal. 4. Install the appearance cover, if equipped. 5. Check for free movement of the accelerator pedal and that there is no binding. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall - (LHD Vehicles) Throttle Cable Replacement > Page 4096 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > 04S25U > Oct > 05 > Recall - (LHD Vehicles) Throttle Cable Replacement > Page 4097 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > NHTSA04V574000 > Dec > 04 > Recall 04V574000: Throttle Cable Replacement Throttle Cable/Linkage: All Technical Service Bulletins Recall 04V574000: Throttle Cable Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Escape 2002-2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 04V574000 Recall Date: Dec 06, 2004 COMPONENT: Vehicle Speed Control: Cables POTENTIAL NUMBER OF UNITS AFFECTED: 470245 SUMMARY: On certain sport utility vehicles built with 3.0L V6 engines, the accelerator cable may prevent the throttle from returning to the idle position. CONSEQUENCE: An unexpected increase in engine idle speed may increase stopping distance and may result in a vehicle crash. REMEDY: Dealers will replace the accelerator cable. The recall is expected to begin on January 17, 2005. Owners should contact Ford at 1-866-436-7332. NOTES: Ford recall No. 04S25. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Page 4102 Torque Specifications Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service Precautions > Technician Safety Information > Page 4105 Throttle Cable/Linkage: Vehicle Damage Warnings CAUTION: Do not pull the accelerator cable out by the cable housing. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service Precautions > Page 4106 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service Precautions > Page 4107 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 crankcase ventilation hose. 2. Remove the bolt, the nuts and the engine appearance cover. 3. Disconnect the accelerator cable from the bracket. 1 Rotate the throttle lever. 2 Slide the accelerator cable end out of the throttle lever. 3 Disconnect the accelerator cable from the bracket. 4. Disconnect the accelerator cable from the pedal. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4110 5. Remove the accelerator cable. CAUTION: Do not pull the accelerator cable out by the cable housing. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4111 Throttle Cable/Linkage: Service and Repair Cable Bracket REMOVAL 1. Disconnect the crankcase ventilation hose. 2. Remove the bolt, nuts and the engine appearance cover. 3. Disconnect the throttle control linkage from the throttle lever. 1 If equipped, disconnect the speed control cable from the throttle lever. 2 Rotate the throttle lever. 3 Slide the accelerator cable end out of the throttle lever. 4. Disconnect the throttle control linkage from the accelerator cable bracket. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4112 1 Disconnect the accelerator cable from the bracket. 2 If equipped, squeeze the tabs and disconnect the speed control cable from the accelerator cable bracket. 5. Remove the bolts and the accelerator cable bracket. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4113 Throttle Cable/Linkage: Service and Repair Pedal and Shaft REMOVAL 1. Disconnect the crankcase ventilation hose. 2. Remove the bolt, the nuts and the engine appearance cover. 3. Disconnect the accelerator cable from the throttle lever. 1 Rotate the throttle lever. 2 Slide the accelerator cable end out of the throttle lever. 4. Remove the accelerator pedal and shaft assembly. 1 Disconnect the accelerator cable. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4114 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4118 Throttle Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4119 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4120 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the nuts and the engine appearance cover. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the sensor NOTE: Air cleaner outlet tube is removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Description and Operation > Intake Manifold Runner Control Variable Induction System: Description and Operation Intake Manifold Runner Control Intake Manifold Runner Control (IMRC) Electric Actuated System Intake Manifold Runner Control (IMRC) - Electric Actuated The Intake Manifold Runner Control (IMRC) Electric Actuated system (Figure 105) consists of a remote mounted motorized actuator with an attaching cable for each housing on each bank. Some applications will use one cable for both banks. The cable or linkage attaches to the housing butterfly plate levers. The 2.0L (2V) Focus/Escort IMRC uses a motorized actuator mounted directly to a single housing without the use of a cable. Each IMRC housing is an aluminum casting with two intake air passages for each cylinder. One passage is always open and the other is opened and closed with a butterfly valve plate. The housing uses a return spring to hold the butterfly valve plates closed. The motorized actuator houses an internal switch or switches, depending on the application, to provide feedback to the PCM indicating cable and butterfly valve plate position. Below approximately 3000 rpm, the motorized actuator will not be energized. This will allow the cable to fully extend and the butterfly valve plates to remain closed. Above approximately 3000 rpm, the motorized actuator will be energized. The attaching cable will pull the butterfly valve plates into the open position. Some vehicles will activate the IMRC near 1500 rpm. WARNING: SUBSTANTIAL OPENING AND CLOSING TORQUE IS APPLIED BY THIS SYSTEM. TO PREVENT INJURY, BE CAREFUL TO KEEP FINGERS AWAY FROM LEVER MECHANISMS WHEN ACTUATED. 1. The PCM uses the Throttle Position (TP) sensor and Crankshaft Position (CKP) signals to determine activation of the IMRC system. There must be a positive change in voltage from the TP sensor along with the increase in rpm to open the valve plates. 2. The PCM uses the information from the input signals to control the IMRC motorized actuator based upon rpm and changes in throttle position. 3. The PCM energizes the actuator to pull the butterfly plates open with the cable(s) or linkage. 4. The IMRC housing contain butterfly plates to allow increased air flow. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Description and Operation > Intake Manifold Runner Control > Page 4125 Variable Induction System: Description and Operation Intake Manifold Swirl Control Intake Manifold Swirl Control (IMSC) Vacuum Actuated System Intake Manifold Swirl Control (IMSC) - Vacuum Actuated The Intake Manifold Swirl Control (IMSC) Vacuum Actuated system (Figure 106) consists of a manifold mounted vacuum actuator and a PCM controlled electric solenoid. The linkage from the actuator attaches to the manifold butterfly plate lever. The IMSC actuator and manifold are composite/plastic with a single intake air passage for each cylinder. The passage has a butterfly valve plate that blocks 60% of the opening when actuated, leaving the top of the passage open to generate turbulence. The housing uses a return spring to hold the butterfly valve plates open. The vacuum actuator houses an internal monitor circuit to provide feedback to the PCM indicating butterfly valve plate position. Below approximately 3000 rpm, the vacuum solenoid will be energized. This will allow manifold vacuum to be applied and the butterfly valve plates to remain closed. Above approximately 3000 rpm, the vacuum solenoid will be de-energized. This will allow vacuum to vent from the actuator and the butterfly valve plates to open. WARNING: SUBSTANTIAL OPENING AND CLOSING TORQUE IS APPLIED BY THIS SYSTEM. TO PREVENT INJURY, BE CAREFUL TO KEEP FINGERS AWAY FROM LEVER MECHANISMS WHEN ACTUATED. 1. The PCM monitors the TP sensor, Cylinder Head Temperature (CHT) and Crankshaft Position (CKP) signals to determine activation of the IMSC system. There must be a positive change in voltage from the TP sensor along with the increase in rpm at the proper engine temperature to open the valve plates. 2. The PCM uses the information from the input signals to control the IMSC electric solenoid based upon changes in throttle position, engine temperature and rpm. 3. The PCM energizes the solenoid with the key on engine running, vacuum is then applied to the actuator to pull the butterfly plates closed. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Description and Operation > Intake Manifold Runner Control > Page 4126 Variable Induction System: Description and Operation Intake Manifold Tuning Valve Intake Manifold Tuning Valve (IMTV) Intake Manifold Tuning Valve (IMTV) The intake manifold tuning valve (IMTV) (Figure 107) is a motorized actuated unit mounted directly to the intake manifold. The IMTV actuator controls a shutter device attached to the actuator shaft. There is no monitor input to the PCM with this system to indicate shutter position. The motorized IMTV unit will not be energized below approximately 2600 rpm or higher on some vehicles. The shutter will be in the closed position not allowing airflow blend to occur in the intake manifold. Above approximately 2600 rpm or higher, the motorized unit will be energized. The motorized unit will be commanded on by the PCM initially at a 100 percent duty cycle to move the shutter to the open position and then falling to approximately 50 percent to continue to hold the shutter open. 1. The PCM uses the TP sensor and CKP signals to determine activation of the IMTV system. There must be a positive change in voltage from the TP sensor along with the increase in rpm to open the shutter. 2. The PCM uses the information from the input signals to control the IMTV. 3. When commanded on by the PCM, the motorized actuator shutter opens up the end of the vertical separating wall at high engine speeds to allow both sides of the manifold to blend together. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications V6 Firing Order: 1 4 2 5 3 6 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 4131 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4139 Camshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 4142 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 4143 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4147 Crankshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor 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 powertrain control module (PCM). The trigger 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 trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 25). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 4150 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 4151 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the bolts and the right front lower splash shield. 3. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4159 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4160 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4161 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4162 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4163 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4164 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 > Page 4167 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 > Page 4168 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 > Page 4169 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 > Page 4170 Ignition Coil: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 > Page 4171 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 > Page 4172 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 > Page 4173 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4174 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4175 Ignition Coil: Description and Operation Coil Pack Horizontal Connector Six Tower Coil Pack Series 5 Six Tower Coil Pack Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4176 Four - Tower Coil Packs Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4177 Series 5 Four Tower Coil Pack 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 56)and (Figure 57). For four-tower coil pack (four cylinder) applications the matched pairs are 1 and 4, and 2 and 3 (Figure 58) and (Figure 59). 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Coil-On-Plug - LH Ignition Coil: Service and Repair Coil-On-Plug - LH REMOVAL 1. Remove the nuts and the engine appearance cover. 2. Remove the ignition coil-on-plug. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the coil-on-plug. INSTALLATION 1. To install, reverse the removal procedure. ^ Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Coil-On-Plug - LH > Page 4180 Ignition Coil: Service and Repair Coil-On-Plug - RH REMOVAL 1. Remove the upper intake manifold. 2. Remove the ignition coil-on-plug. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the coil-on-plug. INSTALLATION 1. To install, reverse the removal procedure. ^ Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 4184 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 4185 View 151-39 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 4186 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 4187 Ignition Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 4188 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4192 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4193 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4194 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the bolt and the KS. NOTE: The KS is located on the RH side of the cylinder block INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ignition Relay: Locations Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 4199 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 4200 View 151-39 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 4201 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 4202 Ignition Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 4203 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4208 Camshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 4211 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 4212 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4216 Crankshaft Position Sensor: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor 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 powertrain control module (PCM). The trigger 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 trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 25). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 4219 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 4220 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the bolts and the right front lower splash shield. 3. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the upper steering column shroud. 3. Remove the screws and the lower steering column shroud. 4. Turn the ignition key to the ON position. 5. Using a small tool, depress the ignition lock cylinder release button and pull the ignition lock cylinder out. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4228 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4229 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4230 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the bolt and the KS. NOTE: The KS is located on the RH side of the cylinder block INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark plug gap..................................................................................................................................... ................................1.3 - 1.4 mm (0.052 - 0.056 inch) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap > Page 4235 Spark Plug: Specifications Torque Spark plugs........................................................................................................................................... ........................................................15 Nm (11 Lb-Ft) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4236 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4237 Spark Plug: Application and ID Spark plug............................................................................................................................................ ...................................................................AWSF-32F Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4238 Spark Plug: Service and Repair REMOVAL 1. Remove the ignition coil-on-plugs. 2. Remove the LH and RH spark plugs. NOTE: LH shown, RH similar. 3. Inspect the spark plugs. INSTALLATION 1. To install, the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations View 151-17 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 4254 Shift Interlock Relay: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 4255 Shift Interlock Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 4256 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations View 151-29 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 4261 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 4262 Four Wheel Drive Selector Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 4263 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs Transmission Mode Switch: Description and Operation PCM Inputs TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs > Page 4270 Transmission Mode Switch: Description and Operation PCM Output Transmission Control Indicator Lamp The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch in Hardware PCM Inputs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Torque Specifications Transmission range (TR) sensor bolts ................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4274 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4275 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4276 Digital Transmission Range 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4277 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4278 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4279 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Transmission Speed Sensor: Customer Interest A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Article No. 02-2-4 02/04/02 TRANSAXLE - CD4E - HARSH AND DELAYED 1-2/2-3 UPSHIFTS - AFTER TRANSAXLE OR TURBINE SHAFT SPEED SENSOR (TSS) REPLACEMENT - POSSIBLE DIAGNOSTIC TROUBLE CODES (DTC) 628, 642, 645, 646, 647, 648, P0731, P0732, P0734, P0741, AND P1744 FORD: 1994-1997 PROBE 1995-2000 CONTOUR 2001-2002 ESCAPE MERCURY: 1995-2000 MYSTIQUE 1999-2002 COUGAR ISSUE Some vehicles equipped with the CD4E transaxle may exhibit harsh and delayed 1-2/2-3 upshifts along with DTCs for gear ratio errors after the Transaxle or Turbine Shaft Speed sensor (TSS) have been replaced. DTCs may include OBD1 codes 628, 642, 645, 646, 647, 648, or OBD II codes P0731, P0732, P0734, P0741, and P1744 ACTION If the condition occurred after servicing the Transaxle or TSS, refer to the following TSS Selection Chart and select the correct TSS for the vehicle application. Note that each TSS has the Ford engineering part number on it. Also note that there is a TSS kit that includes an instruction sheet, TSS sensor and correct bolt. SERVICE PROCEDURE Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored > Page 4288 If the condition occurred after replacing the Transaxle or TSS, use the TSS Selection Chart and determine the correct sensor for the vehicle. 1. Remove the existing TSS from the CD4E pump body. 2. Reinstall the original TSS sensor, if available, or install the correct TSS as indicated in the Selection Chart. 3. Clear all codes and verify repair. 4. If the condition still exists, follow normal diagnostics as listed in the appropriate model year Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T CD4E Harsh and Delayed Upshifts/DTC's Stored Transmission Speed Sensor: All Technical Service Bulletins A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Article No. 02-2-4 02/04/02 TRANSAXLE - CD4E - HARSH AND DELAYED 1-2/2-3 UPSHIFTS - AFTER TRANSAXLE OR TURBINE SHAFT SPEED SENSOR (TSS) REPLACEMENT - POSSIBLE DIAGNOSTIC TROUBLE CODES (DTC) 628, 642, 645, 646, 647, 648, P0731, P0732, P0734, P0741, AND P1744 FORD: 1994-1997 PROBE 1995-2000 CONTOUR 2001-2002 ESCAPE MERCURY: 1995-2000 MYSTIQUE 1999-2002 COUGAR ISSUE Some vehicles equipped with the CD4E transaxle may exhibit harsh and delayed 1-2/2-3 upshifts along with DTCs for gear ratio errors after the Transaxle or Turbine Shaft Speed sensor (TSS) have been replaced. DTCs may include OBD1 codes 628, 642, 645, 646, 647, 648, or OBD II codes P0731, P0732, P0734, P0741, and P1744 ACTION If the condition occurred after servicing the Transaxle or TSS, refer to the following TSS Selection Chart and select the correct TSS for the vehicle application. Note that each TSS has the Ford engineering part number on it. Also note that there is a TSS kit that includes an instruction sheet, TSS sensor and correct bolt. SERVICE PROCEDURE Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T CD4E Harsh and Delayed Upshifts/DTC's Stored > Page 4294 If the condition occurred after replacing the Transaxle or TSS, use the TSS Selection Chart and determine the correct sensor for the vehicle. 1. Remove the existing TSS from the CD4E pump body. 2. Reinstall the original TSS sensor, if available, or install the correct TSS as indicated in the Selection Chart. 3. Clear all codes and verify repair. 4. If the condition still exists, follow normal diagnostics as listed in the appropriate model year Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Page 4295 Transmission Speed Sensor: Specifications Torque 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4298 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Page 4301 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Page 4302 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 sea] as necessary. Installation NOTE: Apply a light coat of petroleum jelly to the O-ring before installation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4305 1. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4306 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Material Materials 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4307 6. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Torque Specifications Vehicle speed sensor (VSS) bolt ........................................................................................................................................................ 7 Nm (62 inch lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Locations > Output Shaft Speed Sensor View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Locations > Output Shaft Speed Sensor > Page 4314 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Diagrams > Output Shaft Speed (OSS) Sensor Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Diagrams > Output Shaft Speed (OSS) Sensor > Page 4317 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Diagrams > Page 4318 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Diagrams > Page 4319 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS)-4x4 Removal and Installation 1. Disconnect the vehicle speed sensor (VSS) electrical connector. 2. Raise the vehicle on the hoist. 3. Remove the bolt and the VSS. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 4324 Four Wheel Drive Selector Switch: Description and Operation 4x4 MODE SWITCH Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 2WD (Figure 46). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 4325 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Remove the mode select switch (MSS) knob. 2. Remove the instrument panel center finish panel. 3. Remove the MSS. 1. Remove the screws. 2. Remove the MSS. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling Technical Service Bulletin # 04S13 Date: 040401 Attachment I - Administrative Information Safety Recall 04S13 Certain 2001-2003 Model Year Escape Vehicles Equipped with 3.0L V6 Engine Powertrain Control Module Re-Calibration Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling > Page 4334 OASIS ACTIVATED? Yes FSA VIN LIST ACTIVATED? Yes available the week of April 12 2004. Available through FMCDealer.com. 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 action. STOCK VEHICLES Correct all affected stock vehicles before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be 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 (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 If a related damage condition exists that you believe to be caused by the covered condition on 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. ADDITIONAL LABOR TIME ^ This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement unless approved. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition call the Special Service Support Center. 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 1904 Dearborn MI 48121. ^ 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 out the VIN for this recall. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 04S13 - Misc. Expense: ADMIN - Misc. Expense: REFUND- Misc. Expense: 0.2 Hrs. RENTAL VEHICLES Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling > Page 4335 The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund 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 Allowances and Parts Ordering Information LABOR ALLOWANCES PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: PCM replacement will not be covered under this program. DEALER PRICE Not applicable. PARTS RETENTION AND RETURN Not applicable. EXCESS STOCK RETURN Not applicable. Attachment III - Technical Information SERVICE PROCEDURE 1. Reprogram the PCM to the latest level calibration. Use one (1) of the following two (2) methods: ^ Worldwide Diagnostic System (WDS), updated to release level B30.7 or later. ^ New Generation STAR (NGS) Tester with Rotunda Flash Cable (007-00531) and Rotunda Flash Card (007-00532). The calibration must be downloaded to a flash card using WDS updated to release level B30.7 or later. NOTE: If the PCM is already programmed to the latest level calibration, reprogramming is not necessary. IF UNABLE TO REPROGRAM PCM ^ PCM replacement will not be covered under this program. ^ Prior to disconnecting the WDS from the vehicle and closing the session, call the Special Service Support Center at 1-800-325-5621. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling > Page 4336 PREPARE AUTHORIZED MODIFICATIONS LABEL 1. Obtain and prepare the Authorized Modifications Label. Describe the modification performed, and enter your P&A; Code, date of repair and the recall program type and program number. See Figure 1. 2. Clean an area on the upper radiator support. 3. Apply the label to this clean area, then cover it with a clear plastic overlay. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling > Page 4337 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling > Page 4338 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > NHTSA04V165000 > Apr > 04 > Recall 04V165000: Engine Stalls on Deceleration PROM - Programmable Read Only Memory: Recalls Recall 04V165000: Engine Stalls on Deceleration DEFECT: On certain sport utility vehicles equipped with 3.0L V6 engines, during decelerations at vehicle speeds below 40 mph, the engine could stall due to excessively rich fuel-air mixtures being sent to the engine. This could result in a crash. REMEDY: Dealers will reprogram the Powertrain Control Module (PCM). The manufacturer has reported that owner notification began on April 21, 2004. Owners may contact Ford at 1-800-392-3673.. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering PROM - Programmable Read Only Memory: Customer Interest Engine Controls/A/T - Unstable Idle/Shuddering TSB 06-11-7 06/12/06 2001-2005 ESCAPE 3.0L UNSTABLE IDLE - 2001-2003 ESCAPE 3.0L AUTOMATIC TRANSAXLE SHUDDER - MEXICO ONLY FORD: 2001-2005 Escape ISSUE Some 2001-2005 Escape vehicles equipped with a 3.0L engine may exhibit idle speeds outside the specified range. Some 2001-2003 Escape vehicles equipped with a 3.0L engine and CD4E automatic transaxle may exhibit a transmission shudder. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. If the concern is a 2001-2005 Escape with idle speeds outside the specified range: a. Install a new idle air control (IAC) valve with jumper harness included in the kit. The new Denso brand IAC will be installed with the electrical connector facing the opposite direction of the original (Hitachi) valve which is why the jumper harness is required. The original (Hitachi) IAC connector faces the front of the vehicle while the new Denso IAC connector faces toward the rear of the vehicle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 4348 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 4349 b. Referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the powertrain control module (PCM) using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 2. If the concern is a 2001 - 2003 Escape with transaxle shudder, drain, flush and refill the transmission fluid with MERCON(R) Multi-Purpose Automatic Transmission Fluid. Then, referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the PCM using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 3. When reprogramming the PCM use blank path programming. Select the proper file from the chart and manually enter the PCM part number or tear tag number to obtain the updated calibration file. To Perform Blank Path Programming: 1. Connect WDS/IDS to vehicle. 2. Select "16 pin", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 5. 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. 6. Screen shows to turn ignition ON. Keep ignition in the "OFF" position, press TICK and you will be asked to cycle the key "ON" and "OFF" a few times. Please keep the key position in the "OFF" position through the key cycles. 7. Screen will show "The diagnostic tester is unable to communicate with this vehicle." You will be prompted to "select a vehicle from the vehicle list", press TICK. 8. A list of vehicles will be displayed, select ALL OTHERS, and press TICK. 9. Screen shows "To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration number (7 digits), Tear Tag number (4 digits), or PCM part number, press TICK. 10. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 11. Follow and answer correctly all remaining screens. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) per Workshop Manual, Section 419-01. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 4350 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9F715 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls/A/T Unstable Idle/Shuddering TSB 06-11-7 06/12/06 2001-2005 ESCAPE 3.0L UNSTABLE IDLE - 2001-2003 ESCAPE 3.0L AUTOMATIC TRANSAXLE SHUDDER - MEXICO ONLY FORD: 2001-2005 Escape ISSUE Some 2001-2005 Escape vehicles equipped with a 3.0L engine may exhibit idle speeds outside the specified range. Some 2001-2003 Escape vehicles equipped with a 3.0L engine and CD4E automatic transaxle may exhibit a transmission shudder. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. If the concern is a 2001-2005 Escape with idle speeds outside the specified range: a. Install a new idle air control (IAC) valve with jumper harness included in the kit. The new Denso brand IAC will be installed with the electrical connector facing the opposite direction of the original (Hitachi) valve which is why the jumper harness is required. The original (Hitachi) IAC connector faces the front of the vehicle while the new Denso IAC connector faces toward the rear of the vehicle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 4356 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 4357 b. Referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the powertrain control module (PCM) using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 2. If the concern is a 2001 - 2003 Escape with transaxle shudder, drain, flush and refill the transmission fluid with MERCON(R) Multi-Purpose Automatic Transmission Fluid. Then, referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the PCM using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 3. When reprogramming the PCM use blank path programming. Select the proper file from the chart and manually enter the PCM part number or tear tag number to obtain the updated calibration file. To Perform Blank Path Programming: 1. Connect WDS/IDS to vehicle. 2. Select "16 pin", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 5. 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. 6. Screen shows to turn ignition ON. Keep ignition in the "OFF" position, press TICK and you will be asked to cycle the key "ON" and "OFF" a few times. Please keep the key position in the "OFF" position through the key cycles. 7. Screen will show "The diagnostic tester is unable to communicate with this vehicle." You will be prompted to "select a vehicle from the vehicle list", press TICK. 8. A list of vehicles will be displayed, select ALL OTHERS, and press TICK. 9. Screen shows "To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration number (7 digits), Tear Tag number (4 digits), or PCM part number, press TICK. 10. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 11. Follow and answer correctly all remaining screens. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) per Workshop Manual, Section 419-01. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 4358 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9F715 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4363 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4364 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling Technical Service Bulletin # 04S13 Date: 040401 Attachment I - Administrative Information Safety Recall 04S13 Certain 2001-2003 Model Year Escape Vehicles Equipped with 3.0L V6 Engine Powertrain Control Module Re-Calibration Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling > Page 4369 OASIS ACTIVATED? Yes FSA VIN LIST ACTIVATED? Yes available the week of April 12 2004. Available through FMCDealer.com. 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 action. STOCK VEHICLES Correct all affected stock vehicles before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be 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 (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 If a related damage condition exists that you believe to be caused by the covered condition on 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. ADDITIONAL LABOR TIME ^ This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement unless approved. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition call the Special Service Support Center. 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 1904 Dearborn MI 48121. ^ 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 out the VIN for this recall. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 04S13 - Misc. Expense: ADMIN - Misc. Expense: REFUND- Misc. Expense: 0.2 Hrs. RENTAL VEHICLES Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling > Page 4370 The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund 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 Allowances and Parts Ordering Information LABOR ALLOWANCES PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: PCM replacement will not be covered under this program. DEALER PRICE Not applicable. PARTS RETENTION AND RETURN Not applicable. EXCESS STOCK RETURN Not applicable. Attachment III - Technical Information SERVICE PROCEDURE 1. Reprogram the PCM to the latest level calibration. Use one (1) of the following two (2) methods: ^ Worldwide Diagnostic System (WDS), updated to release level B30.7 or later. ^ New Generation STAR (NGS) Tester with Rotunda Flash Cable (007-00531) and Rotunda Flash Card (007-00532). The calibration must be downloaded to a flash card using WDS updated to release level B30.7 or later. NOTE: If the PCM is already programmed to the latest level calibration, reprogramming is not necessary. IF UNABLE TO REPROGRAM PCM ^ PCM replacement will not be covered under this program. ^ Prior to disconnecting the WDS from the vehicle and closing the session, call the Special Service Support Center at 1-800-325-5621. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling > Page 4371 PREPARE AUTHORIZED MODIFICATIONS LABEL 1. Obtain and prepare the Authorized Modifications Label. Describe the modification performed, and enter your P&A; Code, date of repair and the recall program type and program number. See Figure 1. 2. Clean an area on the upper radiator support. 3. Apply the label to this clean area, then cover it with a clear plastic overlay. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling > Page 4372 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling > Page 4373 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > NHTSA04V165000 > Apr > 04 > Recall 04V165000: Engine Stalls on Deceleration PROM - Programmable Read Only Memory: All Technical Service Bulletins Recall 04V165000: Engine Stalls on Deceleration DEFECT: On certain sport utility vehicles equipped with 3.0L V6 engines, during decelerations at vehicle speeds below 40 mph, the engine could stall due to excessively rich fuel-air mixtures being sent to the engine. This could result in a crash. REMEDY: Dealers will reprogram the Powertrain Control Module (PCM). The manufacturer has reported that owner notification began on April 21, 2004. Owners may contact Ford at 1-800-392-3673.. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls/A/T Unstable Idle/Shuddering TSB 06-11-7 06/12/06 2001-2005 ESCAPE 3.0L UNSTABLE IDLE - 2001-2003 ESCAPE 3.0L AUTOMATIC TRANSAXLE SHUDDER - MEXICO ONLY FORD: 2001-2005 Escape ISSUE Some 2001-2005 Escape vehicles equipped with a 3.0L engine may exhibit idle speeds outside the specified range. Some 2001-2003 Escape vehicles equipped with a 3.0L engine and CD4E automatic transaxle may exhibit a transmission shudder. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. If the concern is a 2001-2005 Escape with idle speeds outside the specified range: a. Install a new idle air control (IAC) valve with jumper harness included in the kit. The new Denso brand IAC will be installed with the electrical connector facing the opposite direction of the original (Hitachi) valve which is why the jumper harness is required. The original (Hitachi) IAC connector faces the front of the vehicle while the new Denso IAC connector faces toward the rear of the vehicle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 4383 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 4384 b. Referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the powertrain control module (PCM) using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 2. If the concern is a 2001 - 2003 Escape with transaxle shudder, drain, flush and refill the transmission fluid with MERCON(R) Multi-Purpose Automatic Transmission Fluid. Then, referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the PCM using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 3. When reprogramming the PCM use blank path programming. Select the proper file from the chart and manually enter the PCM part number or tear tag number to obtain the updated calibration file. To Perform Blank Path Programming: 1. Connect WDS/IDS to vehicle. 2. Select "16 pin", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 5. 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. 6. Screen shows to turn ignition ON. Keep ignition in the "OFF" position, press TICK and you will be asked to cycle the key "ON" and "OFF" a few times. Please keep the key position in the "OFF" position through the key cycles. 7. Screen will show "The diagnostic tester is unable to communicate with this vehicle." You will be prompted to "select a vehicle from the vehicle list", press TICK. 8. A list of vehicles will be displayed, select ALL OTHERS, and press TICK. 9. Screen shows "To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration number (7 digits), Tear Tag number (4 digits), or PCM part number, press TICK. 10. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 11. Follow and answer correctly all remaining screens. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) per Workshop Manual, Section 419-01. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 4385 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9F715 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4390 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4391 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4397 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4398 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling Technical Service Bulletin # 04S13 Date: 040401 Attachment I - Administrative Information Safety Recall 04S13 Certain 2001-2003 Model Year Escape Vehicles Equipped with 3.0L V6 Engine Powertrain Control Module Re-Calibration Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling > Page 4403 OASIS ACTIVATED? Yes FSA VIN LIST ACTIVATED? Yes available the week of April 12 2004. Available through FMCDealer.com. 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 action. STOCK VEHICLES Correct all affected stock vehicles before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be 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 (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 If a related damage condition exists that you believe to be caused by the covered condition on 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. ADDITIONAL LABOR TIME ^ This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement unless approved. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition call the Special Service Support Center. 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 1904 Dearborn MI 48121. ^ 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 out the VIN for this recall. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 04S13 - Misc. Expense: ADMIN - Misc. Expense: REFUND- Misc. Expense: 0.2 Hrs. RENTAL VEHICLES Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling > Page 4404 The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund 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 Allowances and Parts Ordering Information LABOR ALLOWANCES PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: PCM replacement will not be covered under this program. DEALER PRICE Not applicable. PARTS RETENTION AND RETURN Not applicable. EXCESS STOCK RETURN Not applicable. Attachment III - Technical Information SERVICE PROCEDURE 1. Reprogram the PCM to the latest level calibration. Use one (1) of the following two (2) methods: ^ Worldwide Diagnostic System (WDS), updated to release level B30.7 or later. ^ New Generation STAR (NGS) Tester with Rotunda Flash Cable (007-00531) and Rotunda Flash Card (007-00532). The calibration must be downloaded to a flash card using WDS updated to release level B30.7 or later. NOTE: If the PCM is already programmed to the latest level calibration, reprogramming is not necessary. IF UNABLE TO REPROGRAM PCM ^ PCM replacement will not be covered under this program. ^ Prior to disconnecting the WDS from the vehicle and closing the session, call the Special Service Support Center at 1-800-325-5621. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling > Page 4405 PREPARE AUTHORIZED MODIFICATIONS LABEL 1. Obtain and prepare the Authorized Modifications Label. Describe the modification performed, and enter your P&A; Code, date of repair and the recall program type and program number. See Figure 1. 2. Clean an area on the upper radiator support. 3. Apply the label to this clean area, then cover it with a clear plastic overlay. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling > Page 4406 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04S13 > Apr > 04 > Recall - PCM Recalibration for Engine Stalling > Page 4407 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > NHTSA04V165000 > Apr > 04 > Recall 04V165000: Engine Stalls on Deceleration PROM - Programmable Read Only Memory: All Technical Service Bulletins Recall 04V165000: Engine Stalls on Deceleration DEFECT: On certain sport utility vehicles equipped with 3.0L V6 engines, during decelerations at vehicle speeds below 40 mph, the engine could stall due to excessively rich fuel-air mixtures being sent to the engine. This could result in a crash. REMEDY: Dealers will reprogram the Powertrain Control Module (PCM). The manufacturer has reported that owner notification began on April 21, 2004. Owners may contact Ford at 1-800-392-3673.. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Specifications Accumulator: Specifications Torque Specifications Accumulator body transfer plate bolts ................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Specifications Band Apply Servo: Specifications Intermediate and Overdrive Servo Intermediate/Overdrive Servo Apply Rod Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Specifications > Page 4433 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Specifications > Page 4434 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Specifications > Page 4435 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Specifications > Page 4436 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications Clutch: Specifications Low/Intermediate Carrier Assembly Pinion Gear Reverse Clutch Pack Clearance Forward/Coast Clutch Pack Clearance Direct Clutch Pack Clearance (4 Friction Plates) Low/Reverse Clutch Pack Clearance Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications Differential Fluid - A/T: Capacity Specifications Fluid Capacity 2.0L (Oil Cooler) .................................................................................................................................. .................................................................. 9.0 qts 3.0L (Oil Cooler) ................................................... ............................................................................................................................................... 10.2 qts Differential fluid capacity is fill as necessary with Mercon ATF. Differential is combined in Transmission housing for 4WD. Note: 3.0L 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4445 Differential 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Drain Plug, A/T > Component Information > Specifications Drain Plug: Specifications Torque Specifications Drain plug ............................................................................................................................................ ................................................ 27 Nm (20 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering Fluid - A/T: Customer Interest Engine Controls/A/T - Unstable Idle/Shuddering TSB 06-11-7 06/12/06 2001-2005 ESCAPE 3.0L UNSTABLE IDLE - 2001-2003 ESCAPE 3.0L AUTOMATIC TRANSAXLE SHUDDER - MEXICO ONLY FORD: 2001-2005 Escape ISSUE Some 2001-2005 Escape vehicles equipped with a 3.0L engine may exhibit idle speeds outside the specified range. Some 2001-2003 Escape vehicles equipped with a 3.0L engine and CD4E automatic transaxle may exhibit a transmission shudder. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. If the concern is a 2001-2005 Escape with idle speeds outside the specified range: a. Install a new idle air control (IAC) valve with jumper harness included in the kit. The new Denso brand IAC will be installed with the electrical connector facing the opposite direction of the original (Hitachi) valve which is why the jumper harness is required. The original (Hitachi) IAC connector faces the front of the vehicle while the new Denso IAC connector faces toward the rear of the vehicle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 4457 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 4458 b. Referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the powertrain control module (PCM) using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 2. If the concern is a 2001 - 2003 Escape with transaxle shudder, drain, flush and refill the transmission fluid with MERCON(R) Multi-Purpose Automatic Transmission Fluid. Then, referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the PCM using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 3. When reprogramming the PCM use blank path programming. Select the proper file from the chart and manually enter the PCM part number or tear tag number to obtain the updated calibration file. To Perform Blank Path Programming: 1. Connect WDS/IDS to vehicle. 2. Select "16 pin", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 5. 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. 6. Screen shows to turn ignition ON. Keep ignition in the "OFF" position, press TICK and you will be asked to cycle the key "ON" and "OFF" a few times. Please keep the key position in the "OFF" position through the key cycles. 7. Screen will show "The diagnostic tester is unable to communicate with this vehicle." You will be prompted to "select a vehicle from the vehicle list", press TICK. 8. A list of vehicles will be displayed, select ALL OTHERS, and press TICK. 9. Screen shows "To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration number (7 digits), Tear Tag number (4 digits), or PCM part number, press TICK. 10. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 11. Follow and answer correctly all remaining screens. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) per Workshop Manual, Section 419-01. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 4459 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9F715 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage Fluid - A/T: All 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 4465 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 4466 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-11-7 > Jun > 06 > Engine Controls/A/T Unstable Idle/Shuddering Fluid - A/T: All Technical Service Bulletins Engine Controls/A/T - Unstable Idle/Shuddering TSB 06-11-7 06/12/06 2001-2005 ESCAPE 3.0L UNSTABLE IDLE - 2001-2003 ESCAPE 3.0L AUTOMATIC TRANSAXLE SHUDDER - MEXICO ONLY FORD: 2001-2005 Escape ISSUE Some 2001-2005 Escape vehicles equipped with a 3.0L engine may exhibit idle speeds outside the specified range. Some 2001-2003 Escape vehicles equipped with a 3.0L engine and CD4E automatic transaxle may exhibit a transmission shudder. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. If the concern is a 2001-2005 Escape with idle speeds outside the specified range: a. Install a new idle air control (IAC) valve with jumper harness included in the kit. The new Denso brand IAC will be installed with the electrical connector facing the opposite direction of the original (Hitachi) valve which is why the jumper harness is required. The original (Hitachi) IAC connector faces the front of the vehicle while the new Denso IAC connector faces toward the rear of the vehicle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-11-7 > Jun > 06 > Engine Controls/A/T Unstable Idle/Shuddering > Page 4471 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-11-7 > Jun > 06 > Engine Controls/A/T Unstable Idle/Shuddering > Page 4472 b. Referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the powertrain control module (PCM) using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 2. If the concern is a 2001 - 2003 Escape with transaxle shudder, drain, flush and refill the transmission fluid with MERCON(R) Multi-Purpose Automatic Transmission Fluid. Then, referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the PCM using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 3. When reprogramming the PCM use blank path programming. Select the proper file from the chart and manually enter the PCM part number or tear tag number to obtain the updated calibration file. To Perform Blank Path Programming: 1. Connect WDS/IDS to vehicle. 2. Select "16 pin", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 5. 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. 6. Screen shows to turn ignition ON. Keep ignition in the "OFF" position, press TICK and you will be asked to cycle the key "ON" and "OFF" a few times. Please keep the key position in the "OFF" position through the key cycles. 7. Screen will show "The diagnostic tester is unable to communicate with this vehicle." You will be prompted to "select a vehicle from the vehicle list", press TICK. 8. A list of vehicles will be displayed, select ALL OTHERS, and press TICK. 9. Screen shows "To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration number (7 digits), Tear Tag number (4 digits), or PCM part number, press TICK. 10. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 11. Follow and answer correctly all remaining screens. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) per Workshop Manual, Section 419-01. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-11-7 > Jun > 06 > Engine Controls/A/T Unstable Idle/Shuddering > Page 4473 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9F715 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract > Page 4479 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract > Page 4485 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 2.0L (Oil Cooler) ................................................................................................... .............................................................................................. 10 qts 9.5L 3.0L (Oil Cooler) ................ .............................................................................................................................................................. ................... 10 qts 9.5L Service (Oil Change only) .................................................................................................................... ....................................................................... 3.9 qts Note: 3.0L 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4488 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4489 Fluid - A/T: Service and Repair Transmission Fluid Drain And Refill Removal 1. Raise and support the vehicle. 2. Place a suitable container under the transaxle drain plug. 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. 3. 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 (D DBAZ-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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Locations > Page 4493 Special Tool Seal Removal Transmission Filter Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications Torque Specifications Transaxle cooler lines .......................................................................................................................... ................................................ 23 Nm (17 ft. lbs.) Cooler inlet line ..................................................... .............................................................................................................................. 23 Nm (17 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Torque Specifications Pump assembly bolts .......................................................................................................................... ................................................. 13 Nm (10 ft. lbs.) Pump support bolts .............................................. ................................................................................................................................ 13 Nm (10 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Intermediate Shaft, A/T > Component Information > Specifications Intermediate Shaft: Specifications Torque Specifications Intermediate shaft bearing bracket bolts .............................................................................................................................................. 27 Nm (20 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations View 151-17 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 4507 Shift Interlock Relay: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 4508 Shift Interlock Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 4509 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Differential Fluid Seals-LH > Page 4514 3. Remove the LH halfshaft. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Differential Fluid Seals-LH > Page 4515 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 PTU, remove the PTU. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Differential Fluid Seals-LH > Page 4516 3. NOTE: Place a suitable drain pan under the vehicle. Remove the transaxle drain plug and drain the fluid. 4. Remove the RH halfshaft. 5. If equipped remove the PTU. 6. If the vehicle is equipped with a PTU, use the special tools to remove the RH differential seal. 7. If the vehicle is not equipped with a PTU, use the special tools to remove the RH differential seal. Installation 1. If the vehicle is equipped with a PTU, use the special tools to install the RH differential seal. 2. If the vehicle is not equipped with a PTU, use the special tools to install the RH differential seal. 3. If equipped install the PTU. 4. Install the RH halfshaft. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Differential Fluid Seals-LH > Page 4517 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs Transmission Mode Switch: Description and Operation PCM Inputs TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs > Page 4523 Transmission Mode Switch: Description and Operation PCM Output Transmission Control Indicator Lamp The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch in Hardware PCM Inputs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Torque Specifications Transmission range (TR) sensor bolts ................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4527 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4528 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4529 Digital Transmission Range 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4530 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4531 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4532 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Transmission Speed Sensor: Customer Interest A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Article No. 02-2-4 02/04/02 TRANSAXLE - CD4E - HARSH AND DELAYED 1-2/2-3 UPSHIFTS - AFTER TRANSAXLE OR TURBINE SHAFT SPEED SENSOR (TSS) REPLACEMENT - POSSIBLE DIAGNOSTIC TROUBLE CODES (DTC) 628, 642, 645, 646, 647, 648, P0731, P0732, P0734, P0741, AND P1744 FORD: 1994-1997 PROBE 1995-2000 CONTOUR 2001-2002 ESCAPE MERCURY: 1995-2000 MYSTIQUE 1999-2002 COUGAR ISSUE Some vehicles equipped with the CD4E transaxle may exhibit harsh and delayed 1-2/2-3 upshifts along with DTCs for gear ratio errors after the Transaxle or Turbine Shaft Speed sensor (TSS) have been replaced. DTCs may include OBD1 codes 628, 642, 645, 646, 647, 648, or OBD II codes P0731, P0732, P0734, P0741, and P1744 ACTION If the condition occurred after servicing the Transaxle or TSS, refer to the following TSS Selection Chart and select the correct TSS for the vehicle application. Note that each TSS has the Ford engineering part number on it. Also note that there is a TSS kit that includes an instruction sheet, TSS sensor and correct bolt. SERVICE PROCEDURE Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored > Page 4541 If the condition occurred after replacing the Transaxle or TSS, use the TSS Selection Chart and determine the correct sensor for the vehicle. 1. Remove the existing TSS from the CD4E pump body. 2. Reinstall the original TSS sensor, if available, or install the correct TSS as indicated in the Selection Chart. 3. Clear all codes and verify repair. 4. If the condition still exists, follow normal diagnostics as listed in the appropriate model year Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Transmission Speed Sensor: All Technical Service Bulletins A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Article No. 02-2-4 02/04/02 TRANSAXLE - CD4E - HARSH AND DELAYED 1-2/2-3 UPSHIFTS - AFTER TRANSAXLE OR TURBINE SHAFT SPEED SENSOR (TSS) REPLACEMENT - POSSIBLE DIAGNOSTIC TROUBLE CODES (DTC) 628, 642, 645, 646, 647, 648, P0731, P0732, P0734, P0741, AND P1744 FORD: 1994-1997 PROBE 1995-2000 CONTOUR 2001-2002 ESCAPE MERCURY: 1995-2000 MYSTIQUE 1999-2002 COUGAR ISSUE Some vehicles equipped with the CD4E transaxle may exhibit harsh and delayed 1-2/2-3 upshifts along with DTCs for gear ratio errors after the Transaxle or Turbine Shaft Speed sensor (TSS) have been replaced. DTCs may include OBD1 codes 628, 642, 645, 646, 647, 648, or OBD II codes P0731, P0732, P0734, P0741, and P1744 ACTION If the condition occurred after servicing the Transaxle or TSS, refer to the following TSS Selection Chart and select the correct TSS for the vehicle application. Note that each TSS has the Ford engineering part number on it. Also note that there is a TSS kit that includes an instruction sheet, TSS sensor and correct bolt. SERVICE PROCEDURE Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored > Page 4547 If the condition occurred after replacing the Transaxle or TSS, use the TSS Selection Chart and determine the correct sensor for the vehicle. 1. Remove the existing TSS from the CD4E pump body. 2. Reinstall the original TSS sensor, if available, or install the correct TSS as indicated in the Selection Chart. 3. Clear all codes and verify repair. 4. If the condition still exists, follow normal diagnostics as listed in the appropriate model year Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4548 Transmission Speed Sensor: Specifications Torque 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4551 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Page 4554 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4555 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 sea] as necessary. Installation NOTE: Apply a light coat of petroleum jelly to the O-ring before installation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4558 1. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4559 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Material Materials 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4560 6. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Relay > Component Information > Locations View 151-17 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Relay > Component Information > Locations > Page 4565 Shift Interlock Relay: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Relay > Component Information > Locations > Page 4566 Shift Interlock Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Relay > Component Information > Locations > Page 4567 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications Shifter A/T: Specifications Torque Specifications Manual control lever bolt ..................................................................................................................... ............................................... 27 Nm (20 ft. lbs.) Manual control lever shaft ...................................... ............................................................................................................................. 74 Nm (55 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications > Page 4574 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 ignition switch. 4. Disconnect the gearshift cable. 5. Disconnect the electrical connector. 6. Disconnect the wiring harness from the gear shifter assembly. 7. Remove the bolts and the gearshift lever assembly. 8. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications Shift Cable: Specifications Torque Specifications Shift cable bracket bolts ...................................................................................................................... ................................................ 23 Nm (17 ft. lbs.) Gearshift cable nuts .............................................. ............................................................................................................................ 10 Nm (89 inch lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4579 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4580 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4581 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4582 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4583 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4584 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. 10. Install the upper steering column shroud. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Torque Specifications Torque converter nuts ......................................................................................................................... ................................................. 36 Nm (27 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4592 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4593 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4594 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 4595 Transmission Cooler: Specifications Torque Specifications 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 4596 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 go to the following Symptom Chart. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4599 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > General Procedures Transmission Cooler: Service and Repair General Procedures 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > General Procedures > Page 4602 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > General Procedures > Page 4603 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > General Procedures > Page 4604 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs Transmission Mode Switch: Description and Operation PCM Inputs TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs > Page 4609 Transmission Mode Switch: Description and Operation PCM Output Transmission Control Indicator Lamp The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch in Hardware PCM Inputs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator-Lower, Front > Page 4614 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator-Lower, Front > Page 4615 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator-Lower, Front > Page 4616 Transmission Mount: Service and Repair Transaxle Support Insulator-Lower, Rear Transaxle Support Insulator-Lower, Rear, 3.0L DOHC 1. Disconnect the breather tube and mass air flow (MAF) sensor. 2. Remove the intake tube and air cleaner cover. 3. Remove the air cleaner assembly. 4. Remove the bolts and nuts from the mount, and remove the mount. Installation Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator-Lower, Front > Page 4617 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. Tighten the bolt. 2. Install the air cleaner assembly. 3. Install the intake tube and air cleaner cover. 4. Connect the breather tube and mass air flow (MAF) sensor. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator-Lower, Front > Page 4618 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. 2. Remove the intake tube and air cleaner cover. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator-Lower, Front > Page 4619 3. Remove the air cleaner assembly. 4. Install the special tools. 5. Install the special tools. 6. Remove the upper transaxle mount bolt. 7. Remove the upper transaxle insulator. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator-Lower, Front > Page 4620 8. Remove the top and bottom mount cups. Installation 1. Install the top and bottom mount cups. 2. Install the upper transaxle insulator. 3. Install the upper transaxle bolt. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator-Lower, Front > Page 4621 4. Remove the special tool. 5. Remove the special tool. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Torque Specifications Transmission range (TR) sensor bolts ................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4625 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4626 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4627 Digital Transmission Range 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4628 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4629 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4630 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Transmission Speed Sensor: Customer Interest A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Article No. 02-2-4 02/04/02 TRANSAXLE - CD4E - HARSH AND DELAYED 1-2/2-3 UPSHIFTS - AFTER TRANSAXLE OR TURBINE SHAFT SPEED SENSOR (TSS) REPLACEMENT - POSSIBLE DIAGNOSTIC TROUBLE CODES (DTC) 628, 642, 645, 646, 647, 648, P0731, P0732, P0734, P0741, AND P1744 FORD: 1994-1997 PROBE 1995-2000 CONTOUR 2001-2002 ESCAPE MERCURY: 1995-2000 MYSTIQUE 1999-2002 COUGAR ISSUE Some vehicles equipped with the CD4E transaxle may exhibit harsh and delayed 1-2/2-3 upshifts along with DTCs for gear ratio errors after the Transaxle or Turbine Shaft Speed sensor (TSS) have been replaced. DTCs may include OBD1 codes 628, 642, 645, 646, 647, 648, or OBD II codes P0731, P0732, P0734, P0741, and P1744 ACTION If the condition occurred after servicing the Transaxle or TSS, refer to the following TSS Selection Chart and select the correct TSS for the vehicle application. Note that each TSS has the Ford engineering part number on it. Also note that there is a TSS kit that includes an instruction sheet, TSS sensor and correct bolt. SERVICE PROCEDURE Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored > Page 4639 If the condition occurred after replacing the Transaxle or TSS, use the TSS Selection Chart and determine the correct sensor for the vehicle. 1. Remove the existing TSS from the CD4E pump body. 2. Reinstall the original TSS sensor, if available, or install the correct TSS as indicated in the Selection Chart. 3. Clear all codes and verify repair. 4. If the condition still exists, follow normal diagnostics as listed in the appropriate model year Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Transmission Speed Sensor: All Technical Service Bulletins A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Article No. 02-2-4 02/04/02 TRANSAXLE - CD4E - HARSH AND DELAYED 1-2/2-3 UPSHIFTS - AFTER TRANSAXLE OR TURBINE SHAFT SPEED SENSOR (TSS) REPLACEMENT - POSSIBLE DIAGNOSTIC TROUBLE CODES (DTC) 628, 642, 645, 646, 647, 648, P0731, P0732, P0734, P0741, AND P1744 FORD: 1994-1997 PROBE 1995-2000 CONTOUR 2001-2002 ESCAPE MERCURY: 1995-2000 MYSTIQUE 1999-2002 COUGAR ISSUE Some vehicles equipped with the CD4E transaxle may exhibit harsh and delayed 1-2/2-3 upshifts along with DTCs for gear ratio errors after the Transaxle or Turbine Shaft Speed sensor (TSS) have been replaced. DTCs may include OBD1 codes 628, 642, 645, 646, 647, 648, or OBD II codes P0731, P0732, P0734, P0741, and P1744 ACTION If the condition occurred after servicing the Transaxle or TSS, refer to the following TSS Selection Chart and select the correct TSS for the vehicle application. Note that each TSS has the Ford engineering part number on it. Also note that there is a TSS kit that includes an instruction sheet, TSS sensor and correct bolt. SERVICE PROCEDURE Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored > Page 4645 If the condition occurred after replacing the Transaxle or TSS, use the TSS Selection Chart and determine the correct sensor for the vehicle. 1. Remove the existing TSS from the CD4E pump body. 2. Reinstall the original TSS sensor, if available, or install the correct TSS as indicated in the Selection Chart. 3. Clear all codes and verify repair. 4. If the condition still exists, follow normal diagnostics as listed in the appropriate model year Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4646 Transmission Speed Sensor: Specifications Torque 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor > Page 4649 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page 4652 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4653 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 sea] as necessary. Installation NOTE: Apply a light coat of petroleum jelly to the O-ring before installation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4656 1. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4657 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Material Materials 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4658 6. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Turbine Shaft, A/T > Component Information > Technical Service Bulletins > Customer Interest for Turbine Shaft: > 02-2-4 > Feb > 02 > A/T CD4E Harsh and Delayed Upshifts/DTC's Stored Turbine Shaft: Customer Interest A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Article No. 02-2-4 02/04/02 TRANSAXLE - CD4E - HARSH AND DELAYED 1-2/2-3 UPSHIFTS - AFTER TRANSAXLE OR TURBINE SHAFT SPEED SENSOR (TSS) REPLACEMENT - POSSIBLE DIAGNOSTIC TROUBLE CODES (DTC) 628, 642, 645, 646, 647, 648, P0731, P0732, P0734, P0741, AND P1744 FORD: 1994-1997 PROBE 1995-2000 CONTOUR 2001-2002 ESCAPE MERCURY: 1995-2000 MYSTIQUE 1999-2002 COUGAR ISSUE Some vehicles equipped with the CD4E transaxle may exhibit harsh and delayed 1-2/2-3 upshifts along with DTCs for gear ratio errors after the Transaxle or Turbine Shaft Speed sensor (TSS) have been replaced. DTCs may include OBD1 codes 628, 642, 645, 646, 647, 648, or OBD II codes P0731, P0732, P0734, P0741, and P1744 ACTION If the condition occurred after servicing the Transaxle or TSS, refer to the following TSS Selection Chart and select the correct TSS for the vehicle application. Note that each TSS has the Ford engineering part number on it. Also note that there is a TSS kit that includes an instruction sheet, TSS sensor and correct bolt. SERVICE PROCEDURE Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Turbine Shaft, A/T > Component Information > Technical Service Bulletins > Customer Interest for Turbine Shaft: > 02-2-4 > Feb > 02 > A/T CD4E Harsh and Delayed Upshifts/DTC's Stored > Page 4667 If the condition occurred after replacing the Transaxle or TSS, use the TSS Selection Chart and determine the correct sensor for the vehicle. 1. Remove the existing TSS from the CD4E pump body. 2. Reinstall the original TSS sensor, if available, or install the correct TSS as indicated in the Selection Chart. 3. Clear all codes and verify repair. 4. If the condition still exists, follow normal diagnostics as listed in the appropriate model year Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Turbine Shaft, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Turbine Shaft: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Turbine Shaft: All Technical Service Bulletins A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Article No. 02-2-4 02/04/02 TRANSAXLE - CD4E - HARSH AND DELAYED 1-2/2-3 UPSHIFTS - AFTER TRANSAXLE OR TURBINE SHAFT SPEED SENSOR (TSS) REPLACEMENT - POSSIBLE DIAGNOSTIC TROUBLE CODES (DTC) 628, 642, 645, 646, 647, 648, P0731, P0732, P0734, P0741, AND P1744 FORD: 1994-1997 PROBE 1995-2000 CONTOUR 2001-2002 ESCAPE MERCURY: 1995-2000 MYSTIQUE 1999-2002 COUGAR ISSUE Some vehicles equipped with the CD4E transaxle may exhibit harsh and delayed 1-2/2-3 upshifts along with DTCs for gear ratio errors after the Transaxle or Turbine Shaft Speed sensor (TSS) have been replaced. DTCs may include OBD1 codes 628, 642, 645, 646, 647, 648, or OBD II codes P0731, P0732, P0734, P0741, and P1744 ACTION If the condition occurred after servicing the Transaxle or TSS, refer to the following TSS Selection Chart and select the correct TSS for the vehicle application. Note that each TSS has the Ford engineering part number on it. Also note that there is a TSS kit that includes an instruction sheet, TSS sensor and correct bolt. SERVICE PROCEDURE Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Turbine Shaft, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Turbine Shaft: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored > Page 4673 If the condition occurred after replacing the Transaxle or TSS, use the TSS Selection Chart and determine the correct sensor for the vehicle. 1. Remove the existing TSS from the CD4E pump body. 2. Reinstall the original TSS sensor, if available, or install the correct TSS as indicated in the Selection Chart. 3. Clear all codes and verify repair. 4. If the condition still exists, follow normal diagnostics as listed in the appropriate model year Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications Valve Body: Specifications Torque Specifications Control valve body-to-transfer plate bolts .................................................................................................................................................. 12 Nm (9 ft. lbs.) Main control valve body cover bolts ........................................................................................................................................................ 16 Nm (12 ft. lbs.) Solenoid valve body bolts ........................................................................................... .......................................................................... 10 Nm (89 inch lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4677 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4678 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4679 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4680 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4681 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4682 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4683 5. Loosen the nut on the ball stud for the manual valve detent lever actuating rod assembly. 6. Remove the manual control lever outer assembly bolt. 7. Using the special tool and pin, align the shifter shaft. 8. Move the manual valve detent lever assembly to the "D" position. 9. Tighten the nut on the ball and remove the special tool. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4684 10. Tighten the detent nut. Rotate back to the "D" position and check the adjustment. 11. Using the special tool and pin, align the shifter 12. Install the manual control lever. 13. 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4685 14. Install a new gasket on the main control cover. 15. Install the main control cover, and tighten the bolts in sequence as shown. 16. Install the splash shield. 17. Install the LH front wheel. 18. Lower the vehicle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4686 19. Install the shift cable and bracket. 20. Connect the shift cable. 21. NOTE: Before installing the vent tube hose, clean out any obstructions in the hose using low air pressure. Install the vent tube hose, and clamp. 22. Connect the transaxle harness connector, and the TR sensor connector. 23. Install the intake tube and air cleaner cover. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4687 24. Connect the breather tube and mass air flow (MAF) sensor. 25. 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. 26. 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. 27. 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. 28. Start the engine and move the transaxle range selector lever through all gear positions. Refill as necessary. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications Clutch Disc: Specifications General Specifications Clutch disc Minimum thickness mm (in) ................................................................................................................. ..................................................... 0.3 (0.012) Maximum runout mm (in) ............................................ ........................................................................................................................... 0.7 (0.0276) Clutch disc inner diameter mm (in) ............................................................................................................................................................. 150 (5.91) Clutch disc outer diameter mm (in) ............................................................................................................................................................ 225 (8.86) Maximum runout mm (in) ................................................................................................... .................................................................. 0.700 (0.027) Set load N (lb) ............................................ ............................................................................................................................................ 4900 (1.102) Clutch disc lining thickness Discard thickness from outer face to rivet head mm (in) ........................................................................................................................... 0.3 (0.012) Flywheel side ruin (in) ......................................................................................................................................... ...................................... 3.5 (0.138) Pressure plate side mm (in) ....................................................... ................................................................................................................ 3.5 (0.138) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 4692 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. WARNING: Breathing asbestos dust is hazardous to your health. Failure to follow these instructions may result in personal injury. WARNING: 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. WARNING: 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. WARNING: 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. WARNING: 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. WARNING: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 4693 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 4694 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. NOTE: 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 4695 3. Remove the special tool. 4. Remove the special tool. 5. Install the transaxle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Page 4710 Clutch Master Cylinder: Specifications Torque Specifications Clutch master cylinder nuts ................................................................................................................. ................................................ 23 Nm (17 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Page 4711 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Page 4712 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications Clutch Slave Cylinder: Specifications Torque 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 4716 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications Clutch Pedal Assembly: Specifications General Specifications Clutch pedal disengagement height mm (in) ......................................................................................................................................................... 59 (2.3) Clutch pedal free play mm (in) ........................................................................................................................................................ 506-15.0 (0.22-0.59) Clutch pedal height mm (in) .............................................................................................................................................................. 212-217 (8.35-8.54) Torque Specifications Clutch pedal bracket bolt and nuts ....................................................................................................................................................... 23 Nm (17 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications > Page 4720 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. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations Clutch Switch: Locations The Clutch Switch is located near the left hand rocker panel. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch > Page 4726 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 4733 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-MlC75-B to the transaxle input shaft. 3. Install the flywheel. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications General Specifications Pressure plate diaphragm spring fingers Maximum depth mm (in) ...................................................................................................................... ..................................................... 0.5 (0.020) Maximum clearance mm (in) ....................................... .............................................................................................................................. 0.5 (0.020) Torque Specifications Clutch pressure plate bolts .................................................................................................................. ................................................ 29 Nm (21 ft. lbs.) Torque Sequence Six point star pattern from top clockwise ........................................................................................................................................................ 6-4-2-5-3-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4737 Pressure Plate: Service and Repair Clutch Pressure Plate Locating Dowels Removal 1. Remove the transmission. NOTE: Care should be taken not to damage the dowel holes or the surrounding surface areas during removal. 2. Remove the flywheel dowels. Installation NOTE: Care should be taken to install the dowel squarely into place until it is fully seated and to not damage the surrounding surface areas. 1. Install the flywheel dowels. 2. Install the transmission. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications Differential Cover: Specifications Torque Specifications Differential housing cover retaining bolt ............................................................................................................................................. 23 Nm (17 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 4746 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. 3. Install the differential housing cover and bolts. 4. Fill the rear axle with 1.4 liters (2.95 pints) of rear axle lubricant. ^ Tighten the filler plug. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component Information > Specifications Differential Mount: Specifications Torque Specifications Front insulator bracket-to-subframe bolts .......................................................................................................................................... 115 Nm (85 ft. lbs.) Side insulator bracket-to-subframe bolt ............................................................................................................................................. 115 Nm (85 ft. lbs.) Rear axle differential rear insulator bolt ............................................................................................................................................ 103 Nm (76 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Specifications Differential Axle Housing: Specifications Torque 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications Fill Plug: Specifications Torque Specifications Filler plug ............................................................................................................................................. ............................................... 27 Nm (20 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications With 4-SPD Automatic Differential Oil Capacity 2.0L (Oil Cooler) .................................................................................................................................. ........................................................................ 9.0 qts 3.0L (Oil Cooler) ............................................. ........................................................................................................................................................... 10.2 qts Differential fluid capacity is fill as necessary with Mercon ATF. Differential is combined in Transmission housing for 4WD. Note: 3.0L Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. With 5-SPD Manual Manual Transmission Capacity SAE 75W90 ......................................................................................................................................... ........................................................... 2.2L (2.32 qts.) Note: Fluid level must be even with the bottom of the filler hole. Manual Transmission and Differential are combined in same housing for 4WD. Rear Differential 2WD/4WD Differential Oil Capacity Refill ..................................................................................................................................................... ............................................................. 1.4L (3.0 pts) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4764 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Type ..................................................................................................................................................... ............................... SAE 80W-90 High Performance Ford Part Number ............................................ ............................................................................................................................................. FITZ-19580-B Ford Specification ........................................................................................................ .............................................................................. WSP-M2C197-A Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications Pinion Bearing: Specifications General Specifications Available drive pinion bearing adjustment shim in steps of 0.051 mm (0.002 inch); 0.533-1.092 mm (0.021-0.043 inch) Torque Specifications Pinion bearing preload-(drive pinion collapsible spacer) Used bearings ..................................................................................................................................... .......................... 0.68-1.13 Nm (6-10 inch lbs.) New bearings ............................................................ ...................................................................................................... 1.7-3.4 Nm (15-30 inch lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications Ring Gear: Specifications General Specifications Backlash between ring gear and pinion teeth ............................................................................................................... 0.13-0.20 mm (0.005-0.008 inch) Torque Specifications Ring gear bolt ...................................................................................................................................... .............................................. 109 Nm (80 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Specifications Constant Velocity Joint: Specifications Torque Specifications Front CV joint bolts .............................................................................................................................. ............................................... 40 Nm (30 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Specifications > Page 4776 Constant Velocity Joint: Description and Operation 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Special Tool(s) Part 1 of 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4782 Part 2 of 2 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4783 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4784 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4785 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. 13. If necessary, remove the brake disc shield. Installation All vehicles 1. If necessary, install a disc brake shield. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4786 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4787 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4788 10. Install the wheel hub nut. 11. Install the brake disc. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4789 Wheel Bearing: Service and Repair Rear Suspension Special Tool(s) Part 1 of 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4790 Part 2 of 3 Part 3 of 3 Removal and Installation All vehicles 1. Remove the brake shoes. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4791 2. Remove the rear halfshaft nut. 3. Using the the special tool, loosen the halfshaft from the wheel hub. 4. Using the special tools, remove the wheel hub. 5. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4792 Vehicles with ABS 6. 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 7. Disconnect the parking brake cable. ^ 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. 10. Remove the lower shock absorber nut. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4793 11. NOTE: It may be necessary to hold the ball joint stud to keep it from turning while removing the nut. Disconnect the lower ball joint. ^ Remove the nut. 12. NOTE: It may be necessary to hold the ball joint stud to keep it from turning while removing the nut. Disconnect the upper ball joint. ^ Remove the nut. 13. NOTE: Note the position of the spring insulator and spring for installation. Remove the spring. ^ Lower the support to the wheel knuckle. 14. Remove the wheel knuckle cam bolt. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4794 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 snap ring. 17. Using the special tools, press the outer wheel bearing race from the wheel knuckle. Installation All vehicles 1. Using the special tools, install a new wheel bearing into the wheel knuckle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4795 2. Install the snap ring into the wheel knuckle. 3. Using the special tools, install the wheel hub. 4. Position the wheel knuckle and install the wheel knuckle cam. ^ Position the halfshaft into the wheel hub. 5. Install the wheel knuckle cam bolt loosely. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4796 6. Support the wheel knuckle and install the spring. 7. Install the lower shock absorber nut. 8. Install the upper ball joint. ^ Install the nut. 9. Install the lower ball joint. ^ Install the nut. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4797 10. Tighten the wheel knuckle cam bolt. 1. Align the wheel knuckle cam. 2. Tighten the wheel knuckle cam bolt. 11. Install the brake line to the wheel cylinder. ^ Install the brake line bracket bolt. 12. Install the parking brake cable onto the backing plate. 1. Install the bolt. 2. Install the parking brake cable onto the backing plate. Vehicles with ABS 13. Position the Anti-Lock (ABS) Brake Sensor and bracket bolts. ^ Install the bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4798 14. Using the special tool, install the halfshaft end into the hub assembly. All vehicles 15. Install the halfshaft nut. 16. Install the brake shoes. 17. Bleed the brake system. 18. Check and adjust the wheel alignment as necessary. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Torque Specifications Front Drive Halfshafts Wheel hub nut ..................................................................................................................................... ........................................ 290 Nm (214 ft. lbs.) Rear Drive Halfshafts Rear axle wheel hub nut .............................................................................................................................................................. 290 Nm (214 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications Drive/Propeller Shaft: Specifications General Specifications Torque Specifications Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 4807 Drive/Propeller Shaft: Description and Operation Driveshaft CAUTION: All Driveshaft assemblies are balanced. If undercoating the vehicle, protect the Driveshaft to prevent overspray of any undercoating material. Manual and automatic transmission driveshafts are different. Make sure that the driveshaft being installed is compatible with the vehicle or damage to the vehicle may occur. The driveshaft has traditional balance weights attached (spot-welded) by the manufacturer. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > General Procedures Drive/Propeller Shaft: Service and Repair General Procedures Driveshaft Indexing Driveshaft Indexing NOTE: If a driveshaft is installed and driveshaft vibration is encountered after installation, index the drive shaft. If indexing the driveshaft does not eliminate the vibration, balance the driveshaft. 1. Raise and support the vehicle. 2. Disconnect the front driveshaft and rotate the front flange 60 degrees. 3. Connect the front driveshaft. 4. Disconnect the rear driveshaft universal joint and rotate 180 degrees. 5. Connect the rear driveshaft. 6. Lower the vehicle and test drive. 7. Repeat the procedure if necessary. Driveshaft Runout and Balancing Driveshaft Runout and Balancing 1. Raise and support the vehicle. 2. Remove the rear tires. ^ Install the lug nuts to retain the brake drums. CAUTION: To prevent overheating, do not run the vehicle on the hoist for an extended period of time. 3. ^ Record baseline speed with the transmission in gear. ^ Increase the vehicle speed to the maximum vibration level. ^ Record the speed of the vibration as a baseline. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > General Procedures > Page 4810 4. Check the rear driveshaft attachment. If there are any worn parts, new parts need to be installed. WARNING: Keep hands away from the balance weights while the driveshaft is rotating. 5. With the transmission in gear, run the vehicle with the driveshaft rotating 97 - 113 km/h (60 - 70 mph). 6. Have an assistant contact the driveshaft with a marker in the rear, middle and front end to indicate heavy spots. 7. To balance the driveshaft, install two screw-type hose clamps on the driveshaft and rotate them in 90 degree intervals. Check the vibration for each position and place the screws at the position that produces the least vibration. 8. Run the vehicle at the baseline speed. 9. If the vibration is still evident, rotate the clamps away from each other until the driveshaft is balanced. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > General Procedures > Page 4811 Drive/Propeller Shaft: Service and Repair Removal and Installation 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. 1. Place the selector lever in NEUTRAL. 2. Raise and support the vehicle. 3. Remove the ground strap bolt. CAUTION: Do not reuse the bolts and straps for the pinion yoke. Install new bolts and straps. 4. 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. CAUTION: Do not reuse the CV joint bolts and washers. Install new bolts and washers only or damage to the vehicle may occur. 5. Remove the six front driveshaft to power take off bolts and washers. ^ Discard the bolts and washers. CAUTION: Do not reuse center bearing nuts. Install new nuts only or damage to the vehicle will occur. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > General Procedures > Page 4812 6. With the help of an assistant, remove the drive shaft. ^ Remove and discard the center bearing nuts. 7. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation Universal Joint: Description and Operation Universal Joints The driveshaft is repaired by installing a new complete assembly. The single center joint is: ^ a lubed-for-life design that requires no periodic lubrication. ^ equipped with nylon thrust washers, located at the base of each bearing cup, which control end play, position the needle bearings and improve grease movement. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications 3.0L Flexplate (OHC)................................................................................................................................................... .............................................. 80 Nm 59 ft. lbs (OHV).......................................................................... ............................................................................................................................. 54-64 ft. lbs Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 4819 Flex Plate: Service and Repair Flexplate Removal and Installation 1. Remove the transaxle. 2. Remove the bolts and the flexplate. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications General Specifications Flywheel runout Maximum runout mm (in) ..................................................................................................................... .................................................. 0.2 0.008 in. Torque Specifications Transaxle flywheel housing to engine bolts ............................................................................................................................................ 45 Nm 33 ft. lbs 2.0L Flywheel .............................................................................................................................................. ........................................................... 75-85 ft. lbs 2.0L Zetec Flywheel............................................................................................................................................... ................................................... 112 Nm 83 ft. lbs 3.0L Flexplate/Flywheel (OHC)................................................................................................................................................... .............................................. 80 Nm 59 ft. lbs (OHV).......................................................................... ............................................................................................................................. 54-64 ft. lbs Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair Bell Housing: Service and Repair Clutch Housing Locating Dowels Removal 1. Remove the flywheel. NOTE: Care should be taken not to damage the dowel holes or the surrounding surface areas during removal. 2. Remove the clutch housing locating dowels. Installation NOTE: Care should be taken to install the dowel squarely into place until it is fully seated and to not damage the surrounding surface areas. 1. Install the clutch housing locating dowels. 2. Install the flywheel. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Specifications Case: Specifications Torque Specifications Transaxle case to flywheel housing bolts ............................................................................................................................................. 45 Nm (33 ft. lbs.) Case cover bolts ................................................................................................................ ............................................................... 10 Nm (89 inch lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Specifications > Mechanical Specifications Differential: Mechanical Specifications Torque Specifications Differential cover bolts ......................................................................................................................... ........................................... 164 Nm (121 ft. lbs.) Differential cover screws ........................................ ............................................................................................................................ 9 Nm (80 inch lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Specifications > Mechanical Specifications > Page 4834 Differential: Capacity Specifications Manual Transmission Capacity SAE 75W90 ......................................................................................................................................... ..................................................... 2.2L (2.32 qts.) Note: Fluid level must be even with the bottom of the filler hole. Manual Transmission and Differential are combined in same housing for 4WD. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Component Information > Specifications > Mechanical Specifications > Page 4835 Differential: Fluid Type Specifications Manual Transmission Fluid SAE 75W90 Gear Oil ........................................................................................................................... ............................................. Mazda 115A & API F322-199C547-MA ................................................. ................................................................................................................................................... GL4 Note: Manual Transmission and Differential are combined in same housing. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component Information > Specifications Drain Plug: Specifications Torque Specifications Drain plug ............................................................................................................................................ ................................................ 47 Nm (35 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 ............................................................................................................................................... ................................................................. 2.32 Quarts Note: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 4843 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid Type ..................................................................................................................................................... ...................................... SAE 75W90 Gear OiL GL4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Flywheel Gear, M/T > Component Information > Service and Repair Flywheel 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. CAUTION: Tap the flywheel ring gear evenly to prevent binding. 2. 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 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. 1. Evenly heat the flywheel ring gear. CAUTION: The bevel on the flywheel ring gear must face the rear of the flywheel. 2. Install the flywheel ring gear. ^ Use a brass drift to tap the flywheel ring gear into position. 3. Install the flywheel. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Component Information > Specifications Gear: Specifications General Specifications First gear and differential gear mm (in) ...................................................................................................................................... 0.05-0.33 (0.002-0.013) Second gear and secondary third gear mm (in) ........................................................................................................................... 0.18-0.51 (0.007-0.020) Second gear and third gear mm (in) ............................................................................................................................................ 0.05-0.25 (0.002-0.010) Fourth gear and bearing cone mm (in) ........................................................................................................................................ 0.17-0.42 (0.007-0.017) Backlash Side gears and pinions mm (in) ............................................................................................................................................. 0.025-0.1 (0.001-0.004) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Specifications Input Shaft: Specifications Torque Specifications Input shaft lock nut .............................................................................................................................. ............................................ 160 Nm (118 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Specifications Output Shaft: Specifications Torque Specifications Output shaft locknut ............................................................................................................................. ........................................... 160 Nm (118 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Gear Shaft > Component Information > Specifications Reverse Gear Shaft: Specifications Torque Specifications Reverse idler shaft lock bolt ................................................................................................................ ................................................ 22 Nm (16 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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. NOTE: RH side shown, LH side similar. 2. Remove the halfshaft seal. Installation NOTE: RH side shown, LH side similar. 1. Using the special tool, install the new halfshaft seal. 2. Install the halfshaft. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Torque Specifications Vehicle speed sensor (VSS) bolt ........................................................................................................................................................ 7 Nm (62 inch lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Output Shaft Speed Sensor View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Output Shaft Speed Sensor > Page 4868 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page 4871 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 4872 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 4873 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS)-4x4 Removal and Installation 1. Disconnect the vehicle speed sensor (VSS) electrical connector. 2. Raise the vehicle on the hoist. 3. Remove the bolt and the VSS. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications Shifter M/T: Specifications Torque Specifications Shift control shaft selector lever bolt ................................................................................................................................................... 13 Nm (10 ft. lbs.) Gearshift lever bolts .................................................................................................... ......................................................................... 23 Nm (17 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications > Page 4877 Shifter M/T: Service and Repair Gearshift Lever-4X4 NOTE: Make sure that the gearshift lever is in neutral and the parking brake is set. 1. Remove the center console trim and gearshift lever boot. 1. Remove the gearshift lever knob 2. Remove the center console trim and gearshift boot. NOTE: During installation on vehicles equipped with adjustable shifter cables adjust the shift cable. The second shift cable connection is located under the gearshift lever bracket. 2. Disconnect the shifter cables from the shifter. 3. Remove the shift cable clips. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications > Page 4878 4. Slide the shift cables forward and position them out of the way. 5. Remove the bolts and the gearshift lever. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair Shift Boot: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications Shift Cable: Specifications Torque 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 4886 Shift Cable: Adjustments Gearshift Cable Adjustment NOTE: Make sure that the gearshift lever is in neutral and the parking brake is set. 1. If necessary, remove the center console trim and gearshift lever boot. 1. Remove the gearshift lever knob. 2. Remove the center console trim and gearshift boot. 2. Release the gearshift cable adjuster lock. 3. Release the gearshift cable adjuster. NOTE: The transmission is in neutral when the angle between the gearshift lever and the transmission shift lever is 90 degrees. 4. Set the transmission in neutral. NOTE: Make sure that the gearshift lever is in neutral. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 4887 5. Push in the adjuster and secure the lock. 6. If necessary, install the center console trim, the gearshift lever boot assembly and the gearshift lever knob. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Rail, M/T > Component Information > Specifications Shift Rail: Specifications Torque Specifications Shift rail guide bolt ............................................................................................................................... ................................................. 12 Nm (9 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Specifications Transmission Mount: Specifications Torque Specifications Front transaxle support Insulator bracket bolts ......................................................................................................................... .......................................... 55 Nm (41 ft. lbs.) Insulator bolt ............................................................... ................................................................................................................... 90 Nm (66 ft. lbs.) LH transaxle support Insulator bracket to transaxle bolt and nuts ................................................................................................................................... 90 Nm (66 ft. lbs.) Insulator to bracket bolt ............................................................................................................... .................................................. 90 Nm (66 ft. lbs.) Insulator to body bolts ......................................... .......................................................................................................................... 55 Nm (41 ft. lbs.) Rear transaxle support Insulator bolt ........................................................................................................................................ .......................................... 90 Nm (66 ft. lbs.) Insulator to subframe bolt and nuts ................................................................................................................................................ 90 Nm (66 ft. lbs.) Insulator bracket to transaxle bolts ................................................................................................................................................ 90 Nm (66 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transaxle LH Support Insulator Transmission Mount: Service and Repair Transaxle LH Support Insulator Transaxle LH Support Insulator Special Tool(s) Removal and Installation 1. Using the special tool, support the engine. 2. Remove the air cleaner. 3. Remove the LH transaxle support insulator. 1. Remove the bolt. 2. Remove the four bolts. 3. Remove the LH transaxle support insulator. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transaxle LH Support Insulator > Page 4896 Transmission Mount: Service and Repair Transaxle Front Support Insulator Transaxle Front Support Insulator Special Tool(s) Removal and Installation 1. Using the special tool, support the engine. 2. Remove the front transaxle support insulator bolt. 3. Raise and support the vehicle. 4. Remove the transverse crossmember. 1. Remove the bolts. 2. Remove the transverse crossmember. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transaxle LH Support Insulator > Page 4897 5. Remove the front-to-aft crossmember. 1. Remove the splash shield screw. 2. Remove the bolts and the nut. 3. Remove the front-to-aft crossmember. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transaxle LH Support Insulator > Page 4898 Transmission Mount: Service and Repair Transaxle Rear Support Insulator Transaxle Rear Support Insulator Removal and Installation 1. Remove the rear transaxle support insulator. 1. Remove the bolt. 2. Remove the bolt and the nuts. 3. Remove the rear transaxle support insulator. 2. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Torque Specifications Vehicle speed sensor (VSS) bolt ........................................................................................................................................................ 7 Nm (62 inch lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Locations > Output Shaft Speed Sensor View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Locations > Output Shaft Speed Sensor > Page 4904 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page 4907 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 4908 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 4909 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS)-4x4 Removal and Installation 1. Disconnect the vehicle speed sensor (VSS) electrical connector. 2. Raise the vehicle on the hoist. 3. Remove the bolt and the VSS. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Description and Operation Power Take-Off: Description and Operation POWER TAKE-OFF SWITCH AND CIRCUIT Power Take-Off (PTO) Switch and Circuit To PCM The Power Take-Off (PTO) circuit (Figure 40) is used by the PCM to disable some of the OBD II Monitors during PTO operation. The PTO circuit normally carries low voltage. When the PTO switch is on/closed, B+ is supplied to the PTO input circuit indicating to the PCM that an additional load is being applied to the engine. If this action was not reported by the PTO circuit, a false Diagnostic Trouble Code may be stored. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations View 151-17 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 4918 Shift Interlock Relay: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 4919 Shift Interlock Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 4920 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations View 151-29 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 4925 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 4926 Four Wheel Drive Selector Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 4927 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs Transmission Mode Switch: Description and Operation PCM Inputs TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs > Page 4934 Transmission Mode Switch: Description and Operation PCM Output Transmission Control Indicator Lamp The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch in Hardware PCM Inputs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Torque Specifications Transmission range (TR) sensor bolts ................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4938 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4939 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4940 Digital Transmission Range 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4941 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4942 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4943 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Transmission Speed Sensor: Customer Interest A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Article No. 02-2-4 02/04/02 TRANSAXLE - CD4E - HARSH AND DELAYED 1-2/2-3 UPSHIFTS - AFTER TRANSAXLE OR TURBINE SHAFT SPEED SENSOR (TSS) REPLACEMENT - POSSIBLE DIAGNOSTIC TROUBLE CODES (DTC) 628, 642, 645, 646, 647, 648, P0731, P0732, P0734, P0741, AND P1744 FORD: 1994-1997 PROBE 1995-2000 CONTOUR 2001-2002 ESCAPE MERCURY: 1995-2000 MYSTIQUE 1999-2002 COUGAR ISSUE Some vehicles equipped with the CD4E transaxle may exhibit harsh and delayed 1-2/2-3 upshifts along with DTCs for gear ratio errors after the Transaxle or Turbine Shaft Speed sensor (TSS) have been replaced. DTCs may include OBD1 codes 628, 642, 645, 646, 647, 648, or OBD II codes P0731, P0732, P0734, P0741, and P1744 ACTION If the condition occurred after servicing the Transaxle or TSS, refer to the following TSS Selection Chart and select the correct TSS for the vehicle application. Note that each TSS has the Ford engineering part number on it. Also note that there is a TSS kit that includes an instruction sheet, TSS sensor and correct bolt. SERVICE PROCEDURE Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored > Page 4952 If the condition occurred after replacing the Transaxle or TSS, use the TSS Selection Chart and determine the correct sensor for the vehicle. 1. Remove the existing TSS from the CD4E pump body. 2. Reinstall the original TSS sensor, if available, or install the correct TSS as indicated in the Selection Chart. 3. Clear all codes and verify repair. 4. If the condition still exists, follow normal diagnostics as listed in the appropriate model year Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Transmission Speed Sensor: All Technical Service Bulletins A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Article No. 02-2-4 02/04/02 TRANSAXLE - CD4E - HARSH AND DELAYED 1-2/2-3 UPSHIFTS - AFTER TRANSAXLE OR TURBINE SHAFT SPEED SENSOR (TSS) REPLACEMENT - POSSIBLE DIAGNOSTIC TROUBLE CODES (DTC) 628, 642, 645, 646, 647, 648, P0731, P0732, P0734, P0741, AND P1744 FORD: 1994-1997 PROBE 1995-2000 CONTOUR 2001-2002 ESCAPE MERCURY: 1995-2000 MYSTIQUE 1999-2002 COUGAR ISSUE Some vehicles equipped with the CD4E transaxle may exhibit harsh and delayed 1-2/2-3 upshifts along with DTCs for gear ratio errors after the Transaxle or Turbine Shaft Speed sensor (TSS) have been replaced. DTCs may include OBD1 codes 628, 642, 645, 646, 647, 648, or OBD II codes P0731, P0732, P0734, P0741, and P1744 ACTION If the condition occurred after servicing the Transaxle or TSS, refer to the following TSS Selection Chart and select the correct TSS for the vehicle application. Note that each TSS has the Ford engineering part number on it. Also note that there is a TSS kit that includes an instruction sheet, TSS sensor and correct bolt. SERVICE PROCEDURE Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored > Page 4958 If the condition occurred after replacing the Transaxle or TSS, use the TSS Selection Chart and determine the correct sensor for the vehicle. 1. Remove the existing TSS from the CD4E pump body. 2. Reinstall the original TSS sensor, if available, or install the correct TSS as indicated in the Selection Chart. 3. Clear all codes and verify repair. 4. If the condition still exists, follow normal diagnostics as listed in the appropriate model year Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4959 Transmission Speed Sensor: Specifications Torque 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4962 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Page 4965 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Page 4966 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 sea] as necessary. Installation NOTE: Apply a light coat of petroleum jelly to the O-ring before installation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4969 1. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4970 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Material Materials 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4971 6. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Torque Specifications Vehicle speed sensor (VSS) bolt ........................................................................................................................................................ 7 Nm (62 inch lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Output Shaft Speed Sensor View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Output Shaft Speed Sensor > Page 4978 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page 4981 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 4982 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 4983 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS)-4x4 Removal and Installation 1. Disconnect the vehicle speed sensor (VSS) electrical connector. 2. Raise the vehicle on the hoist. 3. Remove the bolt and the VSS. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 4988 Four Wheel Drive Selector Switch: Description and Operation 4x4 MODE SWITCH Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 2WD (Figure 46). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 4989 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Remove the mode select switch (MSS) knob. 2. Remove the instrument panel center finish panel. 3. Remove the MSS. 1. Remove the screws. 2. Remove the MSS. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Specifications > Capacity Specifications Differential Fluid - Transfer Case: Capacity Specifications Manual Transmission Capacity SAE 75W90 ......................................................................................................................................... ..................................................... 2.2L (2.32 qts.) Note: Fluid level must be even with the bottom of the filler hole. Manual Transmission and Differential are combined in same housing for 4WD. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Specifications > Capacity Specifications > Page 4996 Differential Fluid - Transfer Case: Fluid Type Specifications SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B Ford Specification ................................................................................................................................ ....................................................... WSL-M2C192-A Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Mechanical Specifications Fluid - Transfer Case: Mechanical Specifications Torque Specifications Drain plug ............................................................................................................................................ ............................................. 10 Nm (89 inch lbs.) Fill plug ................................................................. ................................................................................................................................ l6 Nm (12 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Mechanical Specifications > Page 5001 Fluid - Transfer Case: Capacity Specifications Auto/Manual Power Take-Off Unit ....................................................................................................... ........................................................................ 12 oz. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Mechanical Specifications > Page 5002 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ................................................................................................................................................ SAE 75W-140 High Performance Rear Axle Lubricant Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations View 151-29 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 5006 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 5007 Four Wheel Drive Selector Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 5008 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 5012 Four Wheel Drive Selector Switch: Description and Operation 4x4 MODE SWITCH Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 2WD (Figure 46). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 5013 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Remove the mode select switch (MSS) knob. 2. Remove the instrument panel center finish panel. 3. Remove the MSS. 1. Remove the screws. 2. Remove the MSS. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Service and Repair > Transfer Case Rear Output Shaft Flange Output Shaft: Service and Repair Transfer Case Rear Output Shaft Flange Transfer Case Rear Output Shaft Flange Special Tool(s) Removal CAUTION: Mark the driveshaft relative to the companion flange. 1. Remove the driveshaft. CAUTION: Rotational torque of the companion flange must be measured and recorded for correct pinion bearing preload when reassembled. 2. Using the special tool, remove the pinion nut. CAUTION: Mark the companion flange relative to the pinion spline. 3. Using the special tool, remove the companion flange. Installation CAUTION: Install the companion flange to engage the spline as previously marked. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Service and Repair > Transfer Case Rear Output Shaft Flange > Page 5018 1. Using the special tool, install the companion flange. CAUTION: Do not over tighten the pinion nut. Refer to the rotational torque previously recorded. 2. Install the pinion nut. 3. Install the driveshaft. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Service and Repair > Transfer Case Rear Output Shaft Flange > Page 5019 Output Shaft: Service and Repair Transfer Case Rear Output Shaft Flange Dust Shield Transfer Case Rear Output Shaft Flange Dust Shield Special Tool(s) Removal 1. Remove the companion flange. 2. Remove the companion flange dust shield. Installation 1. Using the special tool, install the companion flange dust shield. 2. Install the companion flange. NOTE: Refill capacities are determined by filling the transfer case to the bottom of the filler hole. 3. Check the transfer case oil level. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations View 151-29 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 5024 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 5025 Four Wheel Drive Selector Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 5026 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case Rear Output Shaft Oil Seal Seals and Gaskets: Service and Repair Transfer Case Rear Output Shaft Oil Seal Transfer Case Rear Output Shaft Oil Seal Special Tool(s) Removal 1. Remove the companion flange. 2. Remove the transfer case rear output shaft (pinion) seal. Installation 1. Using the special tool, install the transfer case rear output shaft (pinion) seal. 2. Install the companion flange. 3. Fill the transfer case. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case Rear Output Shaft Oil Seal > Page 5031 Seals and Gaskets: Service and Repair Transfer Case Inner Halfshaft Seal Transfer Case Inner Halfshaft Seal Special Tool(s) Removal 1. Drain the transfer case. 2. Remove the transfer case. 3. Remove the transfer case vent tube. ^ Remove the two bolts. 4. Remove and discard the dust shield. CAUTION: The transfer case cover is located to the case using two hollow dowels. Remove the cover squarely from the dowels to avoid cracking the cover bosses. 5. Remove the bolts and the transfer case cover Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case Rear Output Shaft Oil Seal > Page 5032 6. Remove the three gears 7. Remove the inner seal CAUTION: Transfer case cover and case sealing surfaces must be free of grease prior to applying new silicone sealant. 8. Clean the transfer case sealing surfaces Installation 1. Using the special tool, install the inner seal. 2. Install the three gears. 1. Install the drive gear. 2. Install the idler gear. 3. Install the driven gear. CAUTION: The transfer case cover must be installed within 15 minutes of applying the silicone sealant. If the time limit is exceeded, clean the sealing surfaces and reapply. Apply a 1/8-inch bead of silicone gasket and sealant to the sealing surface of the transfer case cover before installing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case Rear Output Shaft Oil Seal > Page 5033 on the transfer case. 3. Install the transfer case cover. ^ Install the bolts in a cross pattern. 4. Install a new dust shield. 5. Install the transfer case vent tube. ^ Install the bolts. 6. Install the transfer case. 7. Fill the transfer case. 8. Check the transaxle fluid level. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case Rear Output Shaft Oil Seal > Page 5034 Seals and Gaskets: Service and Repair Halfshaft Seal RH Halfshaft Seal RH Special Tool(s) Removal NOTE: If the transfer case is leaking automatic transmission fluid, install a new transfer case driven gear seal. Vehicles with 3.0L engine 1. Remove the exhaust system crossover pipe. 2. Remove the heat shield. ^ Remove the bolts. All vehicles 3. Remove the front drive axle intermediate shaft. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case Rear Output Shaft Oil Seal > Page 5035 4. Remove and discard the dust shield. 5. Remove and discard the RH halfshaft seal. Installation All vehicles 1. Using the special tools, install the RH halfshaft seal. 2. Install the dust shield. 3. NOTE: Clean the intermediate shaft before assembly. Use 600 grit sandpaper on seal journals and wipe dry. Install the front drive axle intermediate shaft. Vehicles with 3.0L engine Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case Rear Output Shaft Oil Seal > Page 5036 4. Install the heat shield. ^ Install the three bolts. 5. Install the exhaust system crossover pipe. All vehicles 6. Check the transfer case oil level. 7. Check the transaxle fluid level. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case Rear Output Shaft Oil Seal > Page 5037 Seals and Gaskets: Service and Repair Transfer Case Driven Gear Seal Transfer Case Driven Gear Seal Special Tool(s) Removal 1. Remove the transfer case. 2. Using the special tools, remove the driven gear seal. Installation Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case Rear Output Shaft Oil Seal > Page 5038 1. NOTE: Clean the inside of the driven gear of foreign material prior to installation. Using the special tools, install the driven gear seal. 2. Install the transfer case. 3. Fill the transfer case. 4. Check the transaxle fluid level. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 5043 Four Wheel Drive Selector Switch: Description and Operation 4x4 MODE SWITCH Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 2WD (Figure 46). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 5044 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Remove the mode select switch (MSS) knob. 2. Remove the instrument panel center finish panel. 3. Remove the MSS. 1. Remove the screws. 2. Remove the MSS. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Locations View 151-17 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Locations > Page 5060 Shift Interlock Relay: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Locations > Page 5061 Shift Interlock Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Locations > Page 5062 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations View 151-29 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 5067 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 5068 Four Wheel Drive Selector Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 5069 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs Transmission Mode Switch: Description and Operation PCM Inputs TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs > Page 5076 Transmission Mode Switch: Description and Operation PCM Output Transmission Control Indicator Lamp The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch in Hardware PCM Inputs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Torque Specifications Transmission range (TR) sensor bolts ................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5080 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5081 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5082 Digital Transmission Range 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5083 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5084 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5085 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Transmission Speed Sensor: Customer Interest A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Article No. 02-2-4 02/04/02 TRANSAXLE - CD4E - HARSH AND DELAYED 1-2/2-3 UPSHIFTS - AFTER TRANSAXLE OR TURBINE SHAFT SPEED SENSOR (TSS) REPLACEMENT - POSSIBLE DIAGNOSTIC TROUBLE CODES (DTC) 628, 642, 645, 646, 647, 648, P0731, P0732, P0734, P0741, AND P1744 FORD: 1994-1997 PROBE 1995-2000 CONTOUR 2001-2002 ESCAPE MERCURY: 1995-2000 MYSTIQUE 1999-2002 COUGAR ISSUE Some vehicles equipped with the CD4E transaxle may exhibit harsh and delayed 1-2/2-3 upshifts along with DTCs for gear ratio errors after the Transaxle or Turbine Shaft Speed sensor (TSS) have been replaced. DTCs may include OBD1 codes 628, 642, 645, 646, 647, 648, or OBD II codes P0731, P0732, P0734, P0741, and P1744 ACTION If the condition occurred after servicing the Transaxle or TSS, refer to the following TSS Selection Chart and select the correct TSS for the vehicle application. Note that each TSS has the Ford engineering part number on it. Also note that there is a TSS kit that includes an instruction sheet, TSS sensor and correct bolt. SERVICE PROCEDURE Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored > Page 5094 If the condition occurred after replacing the Transaxle or TSS, use the TSS Selection Chart and determine the correct sensor for the vehicle. 1. Remove the existing TSS from the CD4E pump body. 2. Reinstall the original TSS sensor, if available, or install the correct TSS as indicated in the Selection Chart. 3. Clear all codes and verify repair. 4. If the condition still exists, follow normal diagnostics as listed in the appropriate model year Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T CD4E Harsh and Delayed Upshifts/DTC's Stored Transmission Speed Sensor: All Technical Service Bulletins A/T - CD4E Harsh and Delayed Upshifts/DTC's Stored Article No. 02-2-4 02/04/02 TRANSAXLE - CD4E - HARSH AND DELAYED 1-2/2-3 UPSHIFTS - AFTER TRANSAXLE OR TURBINE SHAFT SPEED SENSOR (TSS) REPLACEMENT - POSSIBLE DIAGNOSTIC TROUBLE CODES (DTC) 628, 642, 645, 646, 647, 648, P0731, P0732, P0734, P0741, AND P1744 FORD: 1994-1997 PROBE 1995-2000 CONTOUR 2001-2002 ESCAPE MERCURY: 1995-2000 MYSTIQUE 1999-2002 COUGAR ISSUE Some vehicles equipped with the CD4E transaxle may exhibit harsh and delayed 1-2/2-3 upshifts along with DTCs for gear ratio errors after the Transaxle or Turbine Shaft Speed sensor (TSS) have been replaced. DTCs may include OBD1 codes 628, 642, 645, 646, 647, 648, or OBD II codes P0731, P0732, P0734, P0741, and P1744 ACTION If the condition occurred after servicing the Transaxle or TSS, refer to the following TSS Selection Chart and select the correct TSS for the vehicle application. Note that each TSS has the Ford engineering part number on it. Also note that there is a TSS kit that includes an instruction sheet, TSS sensor and correct bolt. SERVICE PROCEDURE Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 02-2-4 > Feb > 02 > A/T CD4E Harsh and Delayed Upshifts/DTC's Stored > Page 5100 If the condition occurred after replacing the Transaxle or TSS, use the TSS Selection Chart and determine the correct sensor for the vehicle. 1. Remove the existing TSS from the CD4E pump body. 2. Reinstall the original TSS sensor, if available, or install the correct TSS as indicated in the Selection Chart. 3. Clear all codes and verify repair. 4. If the condition still exists, follow normal diagnostics as listed in the appropriate model year Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Technical Service Bulletins > Page 5101 Transmission Speed Sensor: Specifications Torque 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5104 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Page 5107 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Page 5108 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 sea] as necessary. Installation NOTE: Apply a light coat of petroleum jelly to the O-ring before installation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5111 1. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5112 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Material Materials 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5113 6. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Torque Specifications Vehicle speed sensor (VSS) bolt ........................................................................................................................................................ 7 Nm (62 inch lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Locations > Output Shaft Speed Sensor View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Locations > Output Shaft Speed Sensor > Page 5120 View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Diagrams > Output Shaft Speed (OSS) Sensor Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Diagrams > Output Shaft Speed (OSS) Sensor > Page 5123 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Diagrams > Page 5124 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 > Diagrams > Page 5125 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS)-4x4 Removal and Installation 1. Disconnect the vehicle speed sensor (VSS) electrical connector. 2. Raise the vehicle on the hoist. 3. Remove the bolt and the VSS. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 5130 Four Wheel Drive Selector Switch: Description and Operation 4x4 MODE SWITCH Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 2WD (Figure 46). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 5131 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Remove the mode select switch (MSS) knob. 2. Remove the instrument panel center finish panel. 3. Remove the MSS. 1. Remove the screws. 2. Remove the MSS. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations View 151-14 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 5137 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5146 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5147 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5148 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5149 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5150 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5151 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5152 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5153 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5154 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5155 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5156 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5157 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5158 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5159 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5160 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5161 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5162 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5163 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5164 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5165 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5166 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5167 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5168 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5169 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5170 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5180 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5181 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5182 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5183 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5184 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5185 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5186 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5187 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5188 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5189 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5190 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5191 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5192 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5193 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5194 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5195 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5196 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5197 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5198 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5199 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5200 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5201 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5202 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5203 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5204 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5209 Electronic Brake Control Module: Specifications Control Module Bolts 9 - 17 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5210 View 151-14 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5211 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5212 Electronic Brake Control Module: Service and Repair Module - Anti-Lock Brake Control Removal and Installation 1. Disconnect the battery negative cable. 2. Remove the air cleaner and the air cleaner outlet pipe. 3. Disconnect the electrical connectors. 4. Remove the bolts. 5. Remove the bolt. 6. Raise and support the vehicle. 7. Remove the screws and the control module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5213 8. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Brake Pressure Control Valve Bolts 80 inch lbs. Hydraulic Control Unit (HCU) To Bracket Bolts 71 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service Precautions > Customer Safety Information Hydraulic Control Assembly - Antilock Brakes: Customer Safety Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service Precautions > Customer Safety Information > Page 5219 Hydraulic Control Assembly - Antilock Brakes: Technician Safety Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service Precautions > Customer Safety Information > Page 5220 Hydraulic Control Assembly - Antilock Brakes: Vehicle Damage Warnings 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service Precautions > Page 5221 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) > Page 5224 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) > Page 5225 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Control Valve 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5230 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 5231 Wheel Speed Sensor: Specifications Front Anti-Lock Brake Sensor Bolt (4X2) 71 - 89 inch lbs. Front Anti-Lock Brake Sensor Bolt (4X4) 71 - 89 inch lbs. Front Anti-Lock Brake Sensor Wire Retaining Bolt (4X4) 62 - 80 inch lbs. Rear Anti-Lock Brake Sensor Bolt 80 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left front > Page 5234 View 151-15 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left front > Page 5235 View 151-27 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left front > Page 5236 View 151-28 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 5239 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 5240 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 5241 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, Front 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5244 6. NOTE: Clean off any dirt that may have collected around the sensor before removal. Remove the bolt and the sensor. 7. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5245 Wheel Speed Sensor: Service and Repair Sensor, Rear Sensor - Rear 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 bolt. 5. Remove the bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5246 6. NOTE: Clean off any dirt that may have collected around the sensor before removal. Remove the bolt and the sensor. 7. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5247 Wheel Speed Sensor: Service and Repair Sensor Ring, Front Sensor Indicator - Front Removal and Installation 1. The front anti-lock brake sensor indicator is attached to the halfshaft. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5248 Wheel Speed Sensor: Service and Repair Sensor Ring, Rear Sensor Indicator - Rear Removal and Installation 1. The rear anti-lock brake sensor indicator is attached to the halfshaft. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service Precautions > Technician Safety Information Brake Bleeding: Technician Safety Information 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: 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. 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service Precautions > Technician Safety Information > Page 5253 Brake Bleeding: Vehicle Damage Warnings 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed Brake Bleeding: Service and Repair Brake Master Cylinder - Bench Bleed 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5256 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5257 Brake Bleeding: Service and Repair Brake Master Cylinder - In-Vehicle Bleed 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. 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 4 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5258 Brake Bleeding: Service and Repair Brake System Gravity Bleeding 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5259 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5260 Brake Bleeding: Service and Repair Brake System Manual Bleeding Manual Bleed 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 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. 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5261 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5262 Brake Bleeding: Service and Repair Brake Master Cylinder - Bench Bleed 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5263 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 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. 2. Install short brake hoses to the master cylinder outlet ports with the ends submerged in the brake master cylinder reservoir. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5264 3. Fill the brake master cylinder reservoir with 4 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. Brake System Gravity Bleeding 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5265 4. Tighten the wheel cylinder bleeder screw. 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 Manual Bleeding Manual Bleed 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5266 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. 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. 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5267 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. 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. Brake System Pressure Bleeding 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 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5268 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5269 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. Four Wheel Antilock Brake System Bleeding 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Pedal Free Play 0.3 - 0.47 inch Brake Pedal Bracket Nuts 17 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 5273 Brake Pedal Assy: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Brakes and Traction Control; Testing and Inspection. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 5274 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Bleeder Screws 71 inch lbs. Disc Brake Caliper Bleeder Screws 12 ft. lbs. Front Disc Brake Caliper Bore 2.36 inch Brake Caliper Anchor Plate Bolts 111 ft. lbs. Brake Caliper Bolts 26 ft. lbs. Brake Line To Caliper 15 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Customer Safety Information Brake Caliper: Customer Safety Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Customer Safety Information > Page 5281 Brake Caliper: Environmental Impact Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Customer Safety Information > Page 5282 Brake Caliper: Technician Safety Information 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. 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. 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. 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Customer Safety Information > Page 5283 Brake Caliper: Vehicle Damage Warnings 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 5286 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 5287 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 5288 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 1. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 5289 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 5290 5. Remove the bolts and brake caliper anchor plate. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Brake Pad: Customer Interest Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Brake Pad: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 5304 Brake Pad: Specifications Brake Lining Thickness 0.50 inch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service Precautions > Environmental Impact Information Brake Pad: Environmental Impact Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service Precautions > Environmental Impact Information > Page 5307 Brake Pad: Technician Safety Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service Precautions > Page 5308 Brake Pad: Service and Repair Brake Pads 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications .............................................................................................................................................................. ........................................................ Min Thickness Front .................................................................................................................................................... .................................................. 0.8661 inch (22mm) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5312 Brake Rotor/Disc: Description and Operation Front Disc Brake The front disc brake system consists of the following components: ^ piston seal ^ piston ^ dust seal ^ caliper ^ caliper bleeder screw ^ caliper bleeder screw cap ^ rotor ^ anchor plate ^ dust shield ^ brake pads The front disc brake system consists of a single-piston front disc brake caliper and a ventilated front disc brake rotor. The brake pads are held in the front disc brake caliper by two front disc brake caliper bolts. To remove the brake disc shield you must remove the wheel knuckle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5313 Brake Rotor/Disc: Testing and Inspection Brake Disc Runout Check Special Tool(s) CAUTION: The brake disc runout specification must be met to make sure of correct brake performance without roughness complaints. CAUTION: Do not install brake discs that are less than the minimum thickness specified. Do not machine a brake disc below the minimum thickness specification. NOTE: When installing brake discs, always align the painted match marks on the brake disc with those on the front hub. NOTE: When installing brake discs, always apply High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-Ml2A4-A to the brake disc-to-front hub mating surfaces. 1. Do not remove the tire and wheel assembly. Tighten the wheel nuts to specification. 2. Raise and support the vehicle. 3. Assemble the special tool, using the spherical tip extension. 4. Locate an opening on the inboard side of the dust shield that will allow the dial indicator tip to be positioned between 5 mm (0.2 in) and 15 mm, (0.6 in) from the outer edge of the brake disc. 5. NOTE: Do not clamp the gauge set to a vehicle component separated from the brake disc by a flexible joint, such as a ball joint or body mount. Clamp the special tool on the vehicle, making sure the flexible indicator arm and probe tip do not touch the dust shield or tire while rotating. 6. Rotate the wheel for six revolutions and record the total indicated runout. 7. If the total runout exceeds the maximum specification, remove the brake disc. 8. Clean the disc brake mounting face of dirt, rust and foreign material. 9. Measure and record the total indicated runout of the hub face outside the stud circle. 10. Install a new front hub if the total indicated runout exceeds the maximum specification. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5314 ^ Repeat the hub runout measurement. 11. If the brake disc total indicated runout is still out of specification, measure and record the thickness of the brake disc. If thickness is sufficient to machine the brake disc to the runout specification, go to Step 12. If the thickness is not sufficient, install a new brake disc and recheck the total indicated runout. 12. NOTE: Brake disc machining must be done with an on-vehicle lathe. Follow the lathe manufacturer's instructions Using the special tool, machine the brake disc if final thickness will not be less than the minimum specification. Recheck the brake disc runout. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5315 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Brake Backing Plate Bolts 49 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 5320 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications .............................................................................................................................................................. .............................................. Max Drum Diameter Rear From 06/12/2007 ........................................................................................................................ ........................................... 9.0590 inch (230.10mm) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service Precautions > Customer Safety Information Brake Drum: Customer Safety Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service Precautions > Customer Safety Information > Page 5326 Brake Drum: Environmental Impact Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service Precautions > Customer Safety Information > Page 5327 Brake Drum: Technician Safety Information 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. CAUTION: Use of a brake drum puller or a torch is not recommended. Brake drum distortion can result. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service Precautions > Page 5328 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service Precautions > Page 5329 2 Loosen the brake shoe adjuster screw nut by adjusting the nut upward. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest for Brake Shoe: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Brake Shoe: Customer Interest Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Brake Shoe: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 5343 Brake Shoe: Specifications Brake Shoe Thickness Minimum 0.04 inch Standard 0.17 inch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 5344 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 5345 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 will also correct out-of-round and bell conditions. Using the special too], 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 5346 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. ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 5347 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Bleeder Screws 71 inch lbs. Wheel Cylinder Inner Diameter 0.937 inch Rear Wheel Cylinder Bolts 9 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service Precautions > Customer Safety Information Wheel Cylinder: Customer Safety Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service Precautions > Customer Safety Information > Page 5353 Wheel Cylinder: Technician Safety Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service Precautions > Customer Safety Information > Page 5354 Wheel Cylinder: Vehicle Damage Warnings 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 5357 2 Release the upper return spring. ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 5358 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service Precautions > Technician Safety Information Brake Bleeding: Technician Safety Information 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: 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. 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service Precautions > Technician Safety Information > Page 5364 Brake Bleeding: Vehicle Damage Warnings 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed Brake Bleeding: Service and Repair Brake Master Cylinder - Bench Bleed 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5367 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5368 Brake Bleeding: Service and Repair Brake Master Cylinder - In-Vehicle Bleed 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. 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 4 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5369 Brake Bleeding: Service and Repair Brake System Gravity Bleeding 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5370 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5371 Brake Bleeding: Service and Repair Brake System Manual Bleeding Manual Bleed 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 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. 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5372 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5373 Brake Bleeding: Service and Repair Brake Master Cylinder - Bench Bleed 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5374 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 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. 2. Install short brake hoses to the master cylinder outlet ports with the ends submerged in the brake master cylinder reservoir. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5375 3. Fill the brake master cylinder reservoir with 4 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. Brake System Gravity Bleeding 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5376 4. Tighten the wheel cylinder bleeder screw. 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 Manual Bleeding Manual Bleed 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5377 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. 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. 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5378 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. 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. Brake System Pressure Bleeding 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 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5379 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 5380 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. Four Wheel Antilock Brake System Bleeding 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Bleeder Screws 71 inch lbs. Disc Brake Caliper Bleeder Screws 12 ft. lbs. Front Disc Brake Caliper Bore 2.36 inch Brake Caliper Anchor Plate Bolts 111 ft. lbs. Brake Caliper Bolts 26 ft. lbs. Brake Line To Caliper 15 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Customer Safety Information Brake Caliper: Customer Safety Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Customer Safety Information > Page 5386 Brake Caliper: Environmental Impact Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Customer Safety Information > Page 5387 Brake Caliper: Technician Safety Information 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. 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. 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. 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Customer Safety Information > Page 5388 Brake Caliper: Vehicle Damage Warnings 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 5391 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 5392 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 5393 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 1. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 5394 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 5395 5. Remove the bolts and brake caliper anchor plate. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Fluid High Performance DOT 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service Precautions > Customer Safety Information Brake Fluid: Customer Safety Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service Precautions > Customer Safety Information > Page 5401 Brake Fluid: Technician Safety Information 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. . Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service Precautions > Customer Safety Information > Page 5402 Brake Fluid: Vehicle Damage Warnings 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Brake Line To Rear Wheel Cylinder Fitting 10 ft. lbs. Brake Line Fitting To Brake Pressure Control Valve Fittings 10 ft. lbs. Brake Line Master Cylinder Fittings 11 ft. lbs. Inlet Brake Line To HCU Nuts (M12- 1) 13 ft. lbs. Outlet Brake Line To HCU Nuts (M12-1) 13 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake Pressure Control Valve Bolts 80 inch lbs. Hydraulic Control Unit (HCU) To Bracket Bolts 71 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service Precautions > Customer Safety Information Hydraulic Control Assembly - Antilock Brakes: Customer Safety Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service Precautions > Customer Safety Information > Page 5414 Hydraulic Control Assembly - Antilock Brakes: Technician Safety Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service Precautions > Customer Safety Information > Page 5415 Hydraulic Control Assembly - Antilock Brakes: Vehicle Damage Warnings 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service Precautions > Page 5416 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) > Page 5419 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) > Page 5420 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Control Valve 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 11 ft. lbs. Brake Master Cylinder Nuts 18 ft. lbs. Power Brake Booster Pushrod Bracket Nuts 17 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service Precautions > Customer Safety Information Brake Master Cylinder: Customer Safety Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service Precautions > Customer Safety Information > Page 5426 Brake Master Cylinder: Technician Safety Information 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. . Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service Precautions > Customer Safety Information > Page 5427 Brake Master Cylinder: Vehicle Damage Warnings 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Brake Master Cylinder 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 5430 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 5431 Brake Master Cylinder: Service and Repair Disassembly and Assembly Brake Master Cylinder 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 5432 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 5433 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 5434 Brake Master Cylinder: Service and Repair Brake Fluid Reservoir 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 5435 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Bleeder Screws 71 inch lbs. Wheel Cylinder Inner Diameter 0.937 inch Rear Wheel Cylinder Bolts 9 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service Precautions > Customer Safety Information Wheel Cylinder: Customer Safety Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service Precautions > Customer Safety Information > Page 5441 Wheel Cylinder: Technician Safety Information 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service Precautions > Customer Safety Information > Page 5442 Wheel Cylinder: Vehicle Damage Warnings 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 5445 2 Release the upper return spring. ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 5446 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 16 ft. lbs. Rear Parking Brake Cable Bracket Bolts 17 ft. lbs. Rear Parking Brake Cable To Knuckle Bracket Bolts 17 ft. lbs. Parking Brake Cable Equalizer Bracket Bolt 80 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable - Front > Page 5453 Parking Brake Cable: Service and Repair Parking Brake Cable - Rear 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable - Front > Page 5454 5. Remove the rear parking brake cable bracket bolts. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable - Front > Page 5455 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications Parking Brake Control: Specifications Parking Brake Control Bolts 18 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5459 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams > Page 5463 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Power Brake Booster Pushrod Bracket Nuts 17 ft. lbs. Master Cylinder Nuts 13 ft. lbs. Purge Valve Bracket Nuts 89 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5468 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5469 Vacuum Brake Booster: Service and Repair Brake Booster 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5470 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5480 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5481 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5482 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5483 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5484 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5485 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5486 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5487 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5488 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5489 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5490 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5491 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5492 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5493 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5494 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5495 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5496 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5497 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5498 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5499 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5500 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5501 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5502 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5503 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5504 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5514 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5515 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5516 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5517 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5518 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5519 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5520 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5521 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5522 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5523 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5524 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5525 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5526 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5527 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5528 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5529 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5530 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5531 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5532 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5533 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5534 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5535 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5536 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5537 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5538 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5543 Electronic Brake Control Module: Specifications Control Module Bolts 9 - 17 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5544 View 151-14 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5545 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5546 Electronic Brake Control Module: Service and Repair Module - Anti-Lock Brake Control Removal and Installation 1. Disconnect the battery negative cable. 2. Remove the air cleaner and the air cleaner outlet pipe. 3. Disconnect the electrical connectors. 4. Remove the bolts. 5. Remove the bolt. 6. Raise and support the vehicle. 7. Remove the screws and the control module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5547 8. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Page 5555 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5560 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 5561 Wheel Speed Sensor: Specifications Front Anti-Lock Brake Sensor Bolt (4X2) 71 - 89 inch lbs. Front Anti-Lock Brake Sensor Bolt (4X4) 71 - 89 inch lbs. Front Anti-Lock Brake Sensor Wire Retaining Bolt (4X4) 62 - 80 inch lbs. Rear Anti-Lock Brake Sensor Bolt 80 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 5564 View 151-15 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 5565 View 151-27 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 5566 View 151-28 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 5569 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 5570 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 5571 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, Front 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5574 6. NOTE: Clean off any dirt that may have collected around the sensor before removal. Remove the bolt and the sensor. 7. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5575 Wheel Speed Sensor: Service and Repair Sensor, Rear Sensor - Rear 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 bolt. 5. Remove the bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5576 6. NOTE: Clean off any dirt that may have collected around the sensor before removal. Remove the bolt and the sensor. 7. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5577 Wheel Speed Sensor: Service and Repair Sensor Ring, Front Sensor Indicator - Front Removal and Installation 1. The front anti-lock brake sensor indicator is attached to the halfshaft. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5578 Wheel Speed Sensor: Service and Repair Sensor Ring, Rear Sensor Indicator - Rear Removal and Installation 1. The rear anti-lock brake sensor indicator is attached to the halfshaft. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Clutch Switch: Locations The Clutch Switch is located near the left hand rocker panel. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch > Page 5586 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the upper steering column shroud. 3. Remove the screws and the lower steering column shroud. 4. Turn the ignition key to the ON position. 5. Using a small tool, depress the ignition lock cylinder release button and pull the ignition lock cylinder out. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Digital Transmission Range Sensor <--> [Neutral Safety Switch] > Component Information > Locations View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Digital Transmission Range Sensor <--> [Neutral Safety Switch] > Component Information > Locations > Page 5594 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5599 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5600 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5601 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5602 Starter Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5603 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 cable. 2 Release the lock clip and pull down on the connector. 5. Remove the bolt from the inner fender bolt. 6. Remove the battery ground cable bolt and the cable from the top of the transaxle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 5608 7. Disconnect the harness clip retainer. 8. Remove the cable ends from starter solenoid. 1 Remove the upper nut. 2 Remove the lower nut. 9. Remove the cable harness from the vehicle. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications Generator: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications > Page 5614 Torque Specifications Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions Generator: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5617 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5618 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5619 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5620 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5621 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5622 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5623 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5624 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5625 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5626 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5627 Generator: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5628 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5629 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5630 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5631 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5632 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5633 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5634 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5635 Generator: Connector Views Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5636 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Page 5637 Generator: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Description and Operation > Standard Models (Non BI-Fuel) Generator: Description and Operation Standard Models (Non BI-Fuel) Generator Load The Generator Load Input (GLI) circuit is used by the PCM to determine generator load on the engine. As generator load increases the PCM will adjust idle speed accordingly. This strategy helps reduce idle surges due to switching high current loads. The GLI signal is sent to the PCM from the voltage regulator/generator. The signal is a variable frequency duty cycle. Normal operating frequency is 40 - 250 Hz. Normal signal DC voltage (referenced to ground) is between 1.5 V (low generator load) and 10.5 V (high generator load). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Description and Operation > Standard Models (Non BI-Fuel) > Page 5640 Generator: Description and Operation The charging system consists of the following components: ^ generator ^ integral voltage regulator The generator maximum output provides 110 amps. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Generator Testing Generator: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Generator Testing > Page 5643 Generator: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Page 5644 Generator: Service and Repair REMOVAL 1. Disconnect the battery cables. 2. Remove the right intermediate axle shaft. 3. Remove the right lower splash shield screws and the pin-type retainer. 4. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt. 5. Remove the nut and position the bracket and wiring harness aside. 6. Remove the upper generator mounting bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Page 5645 7. Remove the lower generator bolts and position the generator aside. 8. Remove the generator mounting bracket bolts and remove the bracket. 9. Remove the generator electrical connectors. 1 Remove the B+ nut and cable. 2 Remove the connector. 10. Rotate the generator to gain clearance, and remove through the opening in the fender well. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations Clutch Switch: Locations The Clutch Switch is located near the left hand rocker panel. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch > Page 5652 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the upper steering column shroud. 3. Remove the screws and the lower steering column shroud. 4. Turn the ignition key to the ON position. 5. Using a small tool, depress the ignition lock cylinder release button and pull the ignition lock cylinder out. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Digital Transmission Range Sensor <--> [Neutral Safety Switch] > Component Information > Locations View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Digital Transmission Range Sensor <--> [Neutral Safety Switch] > Component Information > Locations > Page 5660 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5668 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5669 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5670 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5671 Starter Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5672 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Point <--> [Auxiliary Power Outlet] > Component Information > Diagrams > Power Point, Rear Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Point <--> [Auxiliary Power Outlet] > Component Information > Diagrams > Power Point, Rear > Page 5678 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box Electrical Accessory Panel: Locations Battery Junction Box View 151-12 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5686 View 151-13 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5687 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5688 Electrical Accessory Panel: Locations Central Junction Box View 151-17 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5689 View 151-23 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5690 View 151-38 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5691 View 151-39 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Central Junction Box Electrical Accessory Panel: Diagrams Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Central Junction Box > Page 5694 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Central Junction Box > Page 5695 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Central Junction Box > Page 5696 Electrical Accessory Panel: Diagrams Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Central Junction Box > Page 5697 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5706 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5707 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5708 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5709 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5710 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5711 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5712 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5713 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5719 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5720 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5721 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5722 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5723 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5724 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5725 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5726 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Page 5727 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 5732 Fuse: Locations Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 5733 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 5734 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5737 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5738 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5739 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5740 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5741 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5742 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5743 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5744 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5745 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5746 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5747 Fuse: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5748 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5749 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5750 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5751 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5752 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5753 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5754 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 5757 Fuse: Application and ID Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 5758 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 5759 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 5764 Fuse Block: Locations Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 5765 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 5766 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 Fuse Block: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5783 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5784 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5785 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5786 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5787 Fuse Block: Connector Views Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5788 Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5789 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5790 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5791 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 5794 Fuse Block: Application and ID Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 5795 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 5796 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 5800 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 5804 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5813 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5814 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5815 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5816 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5817 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5823 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5824 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5825 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5826 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5827 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 5830 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 5831 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 5832 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 5833 Multiple Junction Connector: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 5834 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 5835 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 5836 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 5837 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 5838 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 5839 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 5840 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 5841 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 5842 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 5843 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 5844 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations View 151-38 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5848 Accessory Relay (Audio, Instrument Cluster, GEM, & Mirrors) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5849 Power Distribution Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5850 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5855 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5859 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations View 151-38 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5863 Accessory Relay (Audio, Instrument Cluster, GEM, & Mirrors) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5864 Power Distribution Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5865 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5870 Relay Box: Locations Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5871 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5872 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5875 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5876 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5877 Relay Box: Diagrams Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5878 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5881 Relay Box: Application and ID Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5882 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5883 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5888 Relay Box: Locations Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5889 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5890 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box Relay Box: Diagrams Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5893 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5894 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5895 Relay Box: Diagrams Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5896 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5899 Relay Box: Application and ID Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5900 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5901 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5915 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5916 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5917 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5918 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5919 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5920 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5921 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5922 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5923 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5933 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5934 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5935 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5936 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5937 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5938 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5939 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5940 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 5941 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Point <--> [Auxiliary Power Outlet] > Component Information > Diagrams > Power Point, Rear Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Point <--> [Auxiliary Power Outlet] > Component Information > Diagrams > Power Point, Rear > Page 5947 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box Electrical Accessory Panel: Locations Battery Junction Box View 151-12 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5955 View 151-13 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5956 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5957 Electrical Accessory Panel: Locations Central Junction Box View 151-17 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5958 View 151-23 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5959 View 151-38 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5960 View 151-39 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Central Junction Box Electrical Accessory Panel: Diagrams Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Central Junction Box > Page 5963 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Central Junction Box > Page 5964 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Central Junction Box > Page 5965 Electrical Accessory Panel: Diagrams Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Central Junction Box > Page 5966 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5975 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5976 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5977 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5978 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5979 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5980 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5981 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5982 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > System Information > Service and Repair Front Door Panel: Service and Repair REMOVAL Vehicles with power windows 1. Disconnect the battery ground cable. Vehicles with manual windows 2. Remove the front door manual window regulator handle. 1 Release the clip. 2 Remove the front door manual window regulator handle. All vehicles 3. Remove the front door latch release handle bezel. 1 Remove the screw. 2 Remove the front door latch release handle bezel. 4. Remove the door handle cup screw. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > System Information > Service and Repair > Page 5985 5. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 06-11-7 > Jun > 06 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 06-11-7 > Jun > 06 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5995 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 06-11-7 > Jun > 06 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5996 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 06-11-7 > Jun > 06 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5997 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 06-11-7 > Jun > 06 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5998 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 06-11-7 > Jun > 06 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5999 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 06-11-7 > Jun > 06 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6000 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 06-11-7 > Jun > 06 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6001 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Noise Suppressor: > 06-11-7 > Jun > 06 > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6002 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > 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 arms. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6009 Fuse: Locations Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6010 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6011 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6014 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6015 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6016 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6017 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6018 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6019 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6020 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6021 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6022 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6023 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6024 Fuse: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6025 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6026 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6027 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6028 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6029 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6030 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6031 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6034 Fuse: Application and ID Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6035 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6036 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box Fuse Block: Locations Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6041 Fuse Block: Locations Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6042 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6043 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6046 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6047 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6048 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6049 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6050 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6051 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6052 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6053 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6054 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6055 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6056 Fuse Block: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6057 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6058 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6059 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6060 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6061 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6062 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6063 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6064 Fuse Block: Connector Views Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6065 Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6066 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6067 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6068 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 6071 Fuse Block: Application and ID Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 6072 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 6073 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 6077 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 6081 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest: > 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 6090 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 6091 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 6092 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 6093 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 6094 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 6100 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 6101 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 6102 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 6103 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 6104 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multiple Junction Connector: > 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multiple Junction Connector: > 06-21-19 > Oct > 06 > A/C Heater Core Electrolysis/Leakage > Page 6110 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multiple Junction Connector: > 06-21-19 > Oct > 06 > A/C Heater Core Electrolysis/Leakage > Page 6111 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multiple Junction Connector: > 06-21-19 > Oct > 06 > A/C Heater Core Electrolysis/Leakage > Page 6117 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multiple Junction Connector: > 06-21-19 > Oct > 06 > A/C Heater Core Electrolysis/Leakage > Page 6118 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 6121 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 6122 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 6123 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 6124 Multiple Junction Connector: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 6125 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 6126 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 6127 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 6128 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 6129 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 6130 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 6131 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 6132 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 6133 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 6134 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 > Page 6135 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations View 151-38 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6139 Accessory Relay (Audio, Instrument Cluster, GEM, & Mirrors) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6140 Power Distribution Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6141 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 6146 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 6150 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations View 151-38 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6154 Accessory Relay (Audio, Instrument Cluster, GEM, & Mirrors) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6155 Power Distribution Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6156 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6161 Relay Box: Locations Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6162 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6163 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 6166 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 6167 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 6168 Relay Box: Diagrams Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 6169 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6172 Relay Box: Application and ID Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6173 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6174 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6179 Relay Box: Locations Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6180 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6181 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box Relay Box: Diagrams Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 6184 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 6185 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 6186 Relay Box: Diagrams Battery Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 6187 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6190 Relay Box: Application and ID Central Junction Box Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6191 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6192 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6206 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6207 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6208 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6209 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6210 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6211 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6212 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6213 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6214 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6224 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6225 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6226 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6227 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6228 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6229 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6230 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6231 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6232 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6242 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6243 3. Complete worksheet as needed (Figure 5). GENERAL FRONT SUSPENSION UPPER STRUT MOUNT ADJUSTMENT INFORMATION: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6244 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6245 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6251 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6252 3. Complete worksheet as needed (Figure 5). GENERAL FRONT SUSPENSION UPPER STRUT MOUNT ADJUSTMENT INFORMATION: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6253 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6254 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 6255 Alignment: Specifications Front Alignment Specifications Rear Alignment Specifications Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6258 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6259 7. Tighten the nuts. 8. Install the clamp(s). 9. Recheck the toe settings. Follow the equipment manufacturer's instructions. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6260 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6261 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams Power Steering Pressure Switch: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Page 6267 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Power Steering Pressure (PSP) Switch The Power Steering Pressure (PSP) switch (Figure 37) monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Page 6268 Power Steering Pressure Switch: Service and Repair REMOVAL 1. Remove the Power Steering Pressure (PSP) switch. 1 Disconnect the electrical connector. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Steering Knuckle Upper Ball Joint Nut Front Steering Knuckle: Specifications Steering Knuckle Upper Ball Joint Nut Torque Specifications Rear Drive Halfshafts Knuckle bolt ......................................................................................................................................... ....................................... 115 Nm (87 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Steering Knuckle Upper Ball Joint Nut > Page 6274 Front Steering Knuckle: Specifications Ball joint pinch bolt 52 ft. lbs. Lower ball joint nut 85 ft. lbs. Wear Limit See Note The front suspension lower arm ball joint is worn if excessive movement is felt while the wheel is being moved. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 6280 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 2.0 quarts Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 6283 Power Steering Fluid: Fluid Type Specifications MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 89 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 6287 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications Power Steering Fluid Reservoir: Specifications Power steering pump fluid reservoir mounting 89 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Page 6291 Power Steering Fluid Reservoir: Service and Repair Power Steering Fluid Reservoir 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 02-5-2 > Mar > 02 > Power Steering - Leaks in Extreme Cold Power Steering Line/Hose: Customer Interest Power Steering - Leaks in Extreme Cold Article No. 02-5-2 03/01/02 STEERING - POWER STEERING FLUID LEAK DURING EXTREME COLD AMBIENT TEMPERATURES -20 TO -28C (-5 TO -20F) - VEHICLES PRODUCED 2/12/2002 ONLY FORD: 2001-2002 ESCAPE ISSUE Some vehicles built before 2/12/2002 may exhibit a power steering fluid leak at the Return Hose and/or Cooler Hose at the Intermediate Tube Assembly during extreme cold ambient temperatures -20 to -28°C (-5 to -20 °F). This may be caused by hose blow out due to an increase in fluid viscosity during extreme cold temperatures. ACTION Replace the Intermediate Tube with a steel intermediate tube and replace spring type clamps on Return Hose and Cooler Hose with worm type clamps to increase hose retention. SERVICE PROCEDURE 1. Perform procedure in Workshop Manual Section 211-02 to remove Return Hose and Cooler Hose from Intermediate Tube. 2. Replace Intermediate Tube with new part 2L8Z-3A713-AA. 3. Reinstall Cooler and Return Hoses using worm clamps 376240-S100. 4. Bleed all of the air from steering system using bleed procedure in Section 211-00 of the appropriate year Workshop Manual. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020502A Replace Metal Section Of 1.0 Hr. Power Steering Return Hose (Includes Time To Bleed Air From System) DEALER CODING CONDITION BASIC PART NO. CODE 3A713 42 OASIS CODES: 303000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 02-5-2 > Mar > 02 > Power Steering - Leaks in Extreme Cold Power Steering Line/Hose: All Technical Service Bulletins Power Steering - Leaks in Extreme Cold Article No. 02-5-2 03/01/02 STEERING - POWER STEERING FLUID LEAK DURING EXTREME COLD AMBIENT TEMPERATURES -20 TO -28C (-5 TO -20F) - VEHICLES PRODUCED 2/12/2002 ONLY FORD: 2001-2002 ESCAPE ISSUE Some vehicles built before 2/12/2002 may exhibit a power steering fluid leak at the Return Hose and/or Cooler Hose at the Intermediate Tube Assembly during extreme cold ambient temperatures -20 to -28°C (-5 to -20 °F). This may be caused by hose blow out due to an increase in fluid viscosity during extreme cold temperatures. ACTION Replace the Intermediate Tube with a steel intermediate tube and replace spring type clamps on Return Hose and Cooler Hose with worm type clamps to increase hose retention. SERVICE PROCEDURE 1. Perform procedure in Workshop Manual Section 211-02 to remove Return Hose and Cooler Hose from Intermediate Tube. 2. Replace Intermediate Tube with new part 2L8Z-3A713-AA. 3. Reinstall Cooler and Return Hoses using worm clamps 376240-S100. 4. Bleed all of the air from steering system using bleed procedure in Section 211-00 of the appropriate year Workshop Manual. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020502A Replace Metal Section Of 1.0 Hr. Power Steering Return Hose (Includes Time To Bleed Air From System) DEALER CODING CONDITION BASIC PART NO. CODE 3A713 42 OASIS CODES: 303000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 6305 Power Steering Line/Hose: Specifications Power steering pressure line bracket-to-engine insulator bracket bolt, 3.0L (4V) 89 inch lbs. Power steering pressure hose to steering gear fitting 21-25 ft. lbs. Power steering pressure line-to-pump fitting 48 ft. lbs. Power steering pressure and return line retainer plate-to-gear bolt 18 ft. lbs. Power steering pressure line bracket-to-gear bolt 89 inch lbs. Power steering return line bracket-to-gear bolt 89 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 pulley nut, 3.0L (4V) 36 ft. lbs. Power steering pump bracket-to-pump bolts, 3.0L (4V) 18 ft. lbs. Power steering pump bracket mounting nuts, 3.0L (4V) 89 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 6310 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Free flow rate @ 74°-80°C (165°-175°F) and engine set at idle 1.79-2.19 gpm Back pressure @ 74°-80°C (165°-175°F) and engine set at idle (with gate valve open) 60 psi Minimum flow rate @ 74°-80°C (165°-175°F) and 5102 kPa (740 psi) 1.15 gpm Relief pressure 1300-1480 psi Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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-3.0L (4V) Special Tool(s) Removal 1. Remove the ground strap. ^ Remove the nut and the ground strap. 2. Using the special tools, support the engine. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6313 3. Loosen the power steering pump pulley bolt. 4. Remove the drive belt. 5. Remove the bolt and the power steering pump pulley. 6. NOTE: Drain the power steering fluid into a suitable drain pan. Disconnect the power steering low pressure hose. 7. Disconnect the power steering pressure hose and position aside. 1. Remove the power steering pressure line bracket bolt. 2. Disconnect the electrical connector. 3. Disconnect the power steering pressure line and position aside. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6314 8. Remove the upper engine insulator bracket bolt. 9. Remove the A/C line support nut. 10. NOTE: The engine isolator bracket is shown removed for clarity. Remove the engine insulator. 1. Remove the nut. 2. Remove the bolt and the engine insulator. 11. Remove the power steering pump bracket. 1. Remove the pressure line bracket screw. 2. Remove the six nuts. 3. Remove five bolts and the power steering pump bracket. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6315 12. Remove the power steering pump. Installation 1. Position the power steering pump. 2. Install the power steering pump bracket. 1. Install the five bolts. 2. Install the six nuts. 3. Install the pressure line bracket screw. 3. NOTE: The engine isolator bracket is shown removed for clarity. Install the engine insulator. 1. Install the bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6316 2. Install the nut. 4. Install the upper engine insulator bracket bolt. 5. Position the A/C line support and install the nut. 6. 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 special tool and slide it onto the tube nut. 7. Connect the power steering pressure hose. 1. Connect the power steering pressure hose to the pump. 2. Connect the electrical connector. 3. Install the power steering pressure line bracket bolt. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6317 8. Connect the power steering low pressure hose. 9. Install the power steering pump pulley and bolt. 10. Install the drive belt. 11. Tighten the power steering pump pulley bolt. 12. Remove the special tools. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6318 13. Install the ground strap. ^ Position the ground strap and install the nut. 14. Fill, bleed and leak check the power steering system. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6319 Power Steering Pump: Service and Repair Power Steering Pump to Steering Gear Pressure Line Power Steering Pump to Steering Gear Pressure Line-3.0L (4V) Removal 1. Raise and support the vehicle. 2. 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. 3. Lower the vehicle. 4. Remove the power steering pressure line bracket bolt to the steering gear. 5. Remove the power steering pressure hose. 1. Remove the power steering pressure line bracket bolt. 2. Disconnect the electrical connector. 3. Loosen the fitting and remove the power steering pressure line. Installation Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6320 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. 2. Install the power steering pressure hose. 1. Tighten the power steering pressure hose fitting to the pump. 2. Connect the electrical connector. 3. Install the power steering pressure line bracket bolt. 3. Install the power steering pressure line bracket bolt to the steering gear. 4. Raise the vehicle. 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. Install the bolt. 6. Lower the vehicle. 7. Fill, bleed and leak check the power steering system. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6321 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams Power Steering Pressure Switch: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Page 6326 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Power Steering Pressure (PSP) Switch The Power Steering Pressure (PSP) switch (Figure 37) monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Page 6327 Power Steering Pressure Switch: Service and Repair REMOVAL 1. Remove the Power Steering Pressure (PSP) switch. 1 Disconnect the electrical connector. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6334 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6335 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6336 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6337 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6338 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6339 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications Steering Gear Type Rack and pinion Maximum steering gear lateral movement 0.05 inch Steering gear Mounting bolts 35-46 ft. lbs. Mounting bolts 93 inch lbs. coupling pinch bolt 30 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose Steering Gear: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 6345 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 6346 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 6347 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 6348 12. Remove the steering shaft. 13. 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. 16. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 6349 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 6350 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 6351 1. Install the nut. 2. Install the cotter pin. Vehicles equipped with manual transmission 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 6352 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications Steering Shaft: Specifications Steering shaft pinch bolt 18 inch lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 6364 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 6370 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 6371 Steering Wheel: Specifications Steering wheel turning effort 6.75 lb max. Steering wheel pinion shaft 9 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 6372 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 6373 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures > Page 6379 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures > Page 6380 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 6381 Tie Rod End: Specifications Tie rod end jam nuts 35 inch lbs. Tie rod end nut 41 inch lbs. Tie rod end castellated 37 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 6382 Tie Rod End: Service and Repair Tie Rod End 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. 5. Using the special tool, separate the tie rod end. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 6383 6. Remove the tie rod end. 7. To install, reverse the removal procedure. ^ Adjust the front toe. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 6389 Ball Joint: Specifications Rear Suspension Upper ball joint nut 85 ft. lbs. Ball joint pinch bolt 52 ft. lbs. Lower ball joint nut 85 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 6390 Ball Joint: Testing and Inspection Front Lower Balljoint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Reference Diagram ............................................................................................................................. ............................................................................. D Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Steering/Suspension - Control Arm Bushing Inspection > Page 6396 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Steering/Suspension - Control Arm Bushing Inspection > Page 6397 WARRANTY STATUS: Information Only Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Steering Knuckle Upper Ball Joint Nut Front Steering Knuckle: Specifications Steering Knuckle Upper Ball Joint Nut Torque Specifications Rear Drive Halfshafts Knuckle bolt ......................................................................................................................................... ....................................... 115 Nm (87 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Steering Knuckle Upper Ball Joint Nut > Page 6402 Front Steering Knuckle: Specifications Ball joint pinch bolt 52 ft. lbs. Lower ball joint nut 85 ft. lbs. Wear Limit See Note The front suspension lower arm ball joint is worn if excessive movement is felt while the wheel is being moved. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications Spindle: Specifications Wheel knuckle cam bolt 85 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications > Page 6406 Spindle: Service and Repair Wheel Knuckle-4WD Part 1 of 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications > Page 6407 Part 2 of 2 Special Tool(s) Removal and Installation NOTE: When a new wheel knuckle is installed a new wheel bearing must also be installed. All vehicles 1. Raise the vehicle on the hoist. 2. Remove the wheel and tire assembly. 1. If necessary, remove the center cap. 2. Remove the nuts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications > Page 6408 3. CAUTION: Use of a brake drum puller or a torch is not recommended. Brake drum distortion can occur. 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. 4. If the brake drum 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. 5. Remove the rear halfshaft nut. 6. Using the special tool, loosen the halfshaft from the wheel hub. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications > Page 6409 7. Using the special tool, remove the wheel hub. 8. 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. 9. Remove the snap ring. Vehicles with ABS 10. Position the Anti-Lock Brake (ABS) Sensor aside. 1. Remove the ABS sensor bolt and bracket bolts. 2. Position the ABS sensor aside. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications > Page 6410 All vehicles 11. Disconnect the parking brake cable. ^ Remove the parking brake cable bolt from the wheel knuckle. 12. Remove brake line bracket bolt. 13. Support the wheel knuckle. 14. Remove the lower shock absorber nut. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications > Page 6411 15. NOTE: It may be necessary to hold the ball joint stud to keep it from turning while removing the nut. Disconnect the lower ball joint. ^ Remove the nut. 16. NOTE: It may be necessary to hold the ball joint stud to keep it from turning while removing the nut. Disconnect the upper ball joint. ^ Remove the nut. 17. NOTE: Note the position of the spring insulator and spring for installation. Remove the spring. ^ Lower the support to the wheel knuckle. 18. Remove the wheel knuckle cam bolt. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications > Page 6412 1. Mark the position of the adjustment cam notch. 2. Remove the wheel knuckle cam bolt. 19. Remove the wheel knuckle. 1. Remove the wheel knuckle cam. 2. Remove the wheel knuckle. 20. Remove the brake backing plate from the wheel knuckle. 1. Remove the bolts. 2. Remove the brake backing plate from the wheel knuckle and position aside. Installation All vehicles 1. Using the special tools, install a new wheel bearing into the wheel knuckle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications > Page 6413 2. Install the snap ring into the wheel knuckle. 3. Position the wheel knuckle and install the wheel knuckle cam. 4. Install the wheel knuckle cam bolt loosely. 5. NOTE: Brake shoes shown removed for clarity. Install the brake backing plate into the wheel knuckle. ^ Install the bolts. 6. Using the special tools, install the wheel hub. 7. Position the halfshaft into the wheel hub. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications > Page 6414 8. Support the wheel knuckle and install the spring. 9. Install the lower shock absorber nut. 10. Remove the support from the wheel knuckle. 11. Install the upper ball joint. ^ Install the nut. 12. Install the lower ball joint. ^ Install the nut. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications > Page 6415 13. Tighten the wheel knuckle cam bolt. 1. Align the wheel knuckle cam. 2. Tighten the wheel knuckle cam bolt. 14. Install brake line bracket bolt. 15. Install the parking brake cable bolt. Vehicles with ABS 16. Position the ABS brake sensor and bracket bolts. ^ Install the bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications > Page 6416 17. Using the special tool, install the halfshaft end into the hub assembly. All vehicles 18. Install the halfshaft nut. 19. Install the brake drum. 20. Install the wheel and tire assembly. 21. Check and adjust the wheel alignment as necessary. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Specifications Stabilizer Bushing: Specifications Stabilizer bar bushing mount 52 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications Stabilizer bar links 35 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Page 6424 Stabilizer Link: Service and Repair Stabilizer Bar Link 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6434 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6435 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6441 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6442 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 6443 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 6444 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 6445 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 6446 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 6447 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 6448 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 6449 Front Subframe: Service and Repair SUBFRAME - FRONT Special Tool(S) Special Tool(s) Removal and Installation 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 6450 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 bolts. 2 Remove the crossmember. 9. Remove the front transmission mount bolt. 10. Remove the engine support crossmember bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 6451 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 6452 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6461 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6462 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6468 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6469 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6470 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6471 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6472 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6473 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6474 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6475 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6484 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6485 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6491 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6492 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 6493 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 6494 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 6495 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 6496 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 6497 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 6498 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 6499 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 6500 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 6501 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6510 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6511 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6517 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6518 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6519 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6520 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6521 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6522 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6523 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6524 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Page 6528 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises > Page 6537 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises > Page 6538 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises > Page 6544 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises > Page 6545 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber Suspension Strut / Shock Absorber: Specifications Front shock absorber upper mounting bracket nuts 59 ft. lbs. Rear Lower shock absorber 85 ft. lbs. Rear Upper shock absorber nut 13 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber > Page 6548 Suspension Strut / Shock Absorber: Specifications Strut piston rod to bearing plate nut 76 ft. lbs. Strut-to-wheel knuckle bolts 85 ft. lbs. Upper strut mount bolts 59 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Disassembly and Assembly 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Disassembly and Assembly > Page 6551 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Disassembly and Assembly > Page 6552 Suspension Strut / Shock Absorber: Service and Repair Shock Absorber 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Disassembly and Assembly > Page 6553 Suspension Strut / Shock Absorber: Service and Repair Strut and Spring Assembly 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Disassembly and Assembly > Page 6554 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications Trailing Arm: Specifications Rear suspension trailing arm and bushing bolts 85 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Special Tool(s) Part 1 of 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6563 Part 2 of 2 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6564 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6565 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6566 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. 13. If necessary, remove the brake disc shield. Installation All vehicles 1. If necessary, install a disc brake shield. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6567 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6568 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6569 10. Install the wheel hub nut. 11. Install the brake disc. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6570 Wheel Bearing: Service and Repair Rear Suspension Special Tool(s) Part 1 of 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6571 Part 2 of 3 Part 3 of 3 Removal and Installation All vehicles 1. Remove the brake shoes. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6572 2. Remove the rear halfshaft nut. 3. Using the the special tool, loosen the halfshaft from the wheel hub. 4. Using the special tools, remove the wheel hub. 5. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6573 Vehicles with ABS 6. 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 7. Disconnect the parking brake cable. ^ 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. 10. Remove the lower shock absorber nut. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6574 11. NOTE: It may be necessary to hold the ball joint stud to keep it from turning while removing the nut. Disconnect the lower ball joint. ^ Remove the nut. 12. NOTE: It may be necessary to hold the ball joint stud to keep it from turning while removing the nut. Disconnect the upper ball joint. ^ Remove the nut. 13. NOTE: Note the position of the spring insulator and spring for installation. Remove the spring. ^ Lower the support to the wheel knuckle. 14. Remove the wheel knuckle cam bolt. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6575 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 snap ring. 17. Using the special tools, press the outer wheel bearing race from the wheel knuckle. Installation All vehicles 1. Using the special tools, install a new wheel bearing into the wheel knuckle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6576 2. Install the snap ring into the wheel knuckle. 3. Using the special tools, install the wheel hub. 4. Position the wheel knuckle and install the wheel knuckle cam. ^ Position the halfshaft into the wheel hub. 5. Install the wheel knuckle cam bolt loosely. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6577 6. Support the wheel knuckle and install the spring. 7. Install the lower shock absorber nut. 8. Install the upper ball joint. ^ Install the nut. 9. Install the lower ball joint. ^ Install the nut. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6578 10. Tighten the wheel knuckle cam bolt. 1. Align the wheel knuckle cam. 2. Tighten the wheel knuckle cam bolt. 11. Install the brake line to the wheel cylinder. ^ Install the brake line bracket bolt. 12. Install the parking brake cable onto the backing plate. 1. Install the bolt. 2. Install the parking brake cable onto the backing plate. Vehicles with ABS 13. Position the Anti-Lock (ABS) Brake Sensor and bracket bolts. ^ Install the bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6579 14. Using the special tool, install the halfshaft end into the hub assembly. All vehicles 15. Install the halfshaft nut. 16. Install the brake shoes. 17. Bleed the brake system. 18. Check and adjust the wheel alignment as necessary. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Torque Specifications Front Drive Halfshafts Wheel hub nut ..................................................................................................................................... ........................................ 290 Nm (214 ft. lbs.) Rear Drive Halfshafts Rear axle wheel hub nut .............................................................................................................................................................. 290 Nm (214 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 1. The front jacking point is at the bolt head of the lower control arm. Jacking Points - Rear 1. The rear jacking points are located on the rear trailing arms. LIFTING Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 6588 Lifting Points 1. The lifting points are part of the uni-body structure. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 6593 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Wheels: Customer Interest Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-11-2 > Jun > 02 > Brakes - Excessive Brake Dust on Wheels Wheels: All Technical Service Bulletins Brakes - Excessive Brake Dust on Wheels Article No. 02-11-2 06/10/02 BRAKES - EXCESSIVE BRAKE DUST - INFORMATION AND CLEANING TIPS FORD: 1999-2002 ESCORT 1999-2003 CROWN VICTORIA 2000-2002 FOCUS 2001-2002 ESCAPE MERCURY: 1999-2003 GRAND MARQUIS ISSUE Under normal operating conditions, customers may notice accumulation of brake dust on their wheels. Some brake dust is inevitable as brakes wear and does not contribute to brake noise. The use of modern friction materials with emphasis on improved performance and environmental considerations can lead to more dust than in the past. ACTION Brake dust can be cleaned by weekly washing with Motorcraft Detail Wash (ZC-3-A) and a soft sponge. Heavier deposits can be removed with Motorcraft Wheel and Tire Cleaner (ZC-37-A). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 301000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 6611 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 6617 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6618 Wheels: Specifications Type Wheel Runout Aluminum Max. Radial Runout 0.06 inch Max. Lateral Runout 0.08 inch Steel Max. Radial Runout 0.06 inch Max. Lateral Runout 0.08 inch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Special Tool(s) Part 1 of 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6624 Part 2 of 2 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6625 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6626 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6627 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. 13. If necessary, remove the brake disc shield. Installation All vehicles 1. If necessary, install a disc brake shield. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6628 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6629 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6630 10. Install the wheel hub nut. 11. Install the brake disc. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6631 Wheel Bearing: Service and Repair Rear Suspension Special Tool(s) Part 1 of 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6632 Part 2 of 3 Part 3 of 3 Removal and Installation All vehicles 1. Remove the brake shoes. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6633 2. Remove the rear halfshaft nut. 3. Using the the special tool, loosen the halfshaft from the wheel hub. 4. Using the special tools, remove the wheel hub. 5. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6634 Vehicles with ABS 6. 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 7. Disconnect the parking brake cable. ^ 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. 10. Remove the lower shock absorber nut. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6635 11. NOTE: It may be necessary to hold the ball joint stud to keep it from turning while removing the nut. Disconnect the lower ball joint. ^ Remove the nut. 12. NOTE: It may be necessary to hold the ball joint stud to keep it from turning while removing the nut. Disconnect the upper ball joint. ^ Remove the nut. 13. NOTE: Note the position of the spring insulator and spring for installation. Remove the spring. ^ Lower the support to the wheel knuckle. 14. Remove the wheel knuckle cam bolt. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6636 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 snap ring. 17. Using the special tools, press the outer wheel bearing race from the wheel knuckle. Installation All vehicles 1. Using the special tools, install a new wheel bearing into the wheel knuckle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6637 2. Install the snap ring into the wheel knuckle. 3. Using the special tools, install the wheel hub. 4. Position the wheel knuckle and install the wheel knuckle cam. ^ Position the halfshaft into the wheel hub. 5. Install the wheel knuckle cam bolt loosely. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6638 6. Support the wheel knuckle and install the spring. 7. Install the lower shock absorber nut. 8. Install the upper ball joint. ^ Install the nut. 9. Install the lower ball joint. ^ Install the nut. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6639 10. Tighten the wheel knuckle cam bolt. 1. Align the wheel knuckle cam. 2. Tighten the wheel knuckle cam bolt. 11. Install the brake line to the wheel cylinder. ^ Install the brake line bracket bolt. 12. Install the parking brake cable onto the backing plate. 1. Install the bolt. 2. Install the parking brake cable onto the backing plate. Vehicles with ABS 13. Position the Anti-Lock (ABS) Brake Sensor and bracket bolts. ^ Install the bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 6640 14. Using the special tool, install the halfshaft end into the hub assembly. All vehicles 15. Install the halfshaft nut. 16. Install the brake shoes. 17. Bleed the brake system. 18. Check and adjust the wheel alignment as necessary. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Torque Specifications Front Drive Halfshafts Wheel hub nut ..................................................................................................................................... ........................................ 290 Nm (214 ft. lbs.) Rear Drive Halfshafts Rear axle wheel hub nut .............................................................................................................................................................. 290 Nm (214 ft. lbs.) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel nuts (all wheels) 98 ft. lbs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Studs Removal and Installation 1. Remove the front wheel bearing. 2. Press out the wheel studs. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 6650 Wheel Fastener: Service and Repair Rear Suspension Wheel Studs Removal and Installation 1. Remove the wheel bearing. 2. Press out the wheel studs. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 6655 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 6656 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 6657 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 6658 Accumulator HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6664 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6665 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6666 Air Door Actuator / Motor: Service and Repair Outside Air Inlet 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Page 6670 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Page 6671 Alignment Pin, Temperature Blend Door Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct > Page 6676 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct > Page 6677 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct > Page 6678 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct > Page 6679 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest: > 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest: > 04-25-13 > Dec > 04 > A/C - Instrument Panel Vents Hard to Adjust > Page 6688 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-25-13 > Dec > 04 > A/C - Instrument Panel Vents Hard to Adjust > Page 6694 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine Controls/A/T - Unstable Idle/Shuddering TSB 06-11-7 06/12/06 2001-2005 ESCAPE 3.0L UNSTABLE IDLE - 2001-2003 ESCAPE 3.0L AUTOMATIC TRANSAXLE SHUDDER - MEXICO ONLY FORD: 2001-2005 Escape ISSUE Some 2001-2005 Escape vehicles equipped with a 3.0L engine may exhibit idle speeds outside the specified range. Some 2001-2003 Escape vehicles equipped with a 3.0L engine and CD4E automatic transaxle may exhibit a transmission shudder. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. If the concern is a 2001-2005 Escape with idle speeds outside the specified range: a. Install a new idle air control (IAC) valve with jumper harness included in the kit. The new Denso brand IAC will be installed with the electrical connector facing the opposite direction of the original (Hitachi) valve which is why the jumper harness is required. The original (Hitachi) IAC connector faces the front of the vehicle while the new Denso IAC connector faces toward the rear of the vehicle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 6700 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 6701 b. Referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the powertrain control module (PCM) using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 2. If the concern is a 2001 - 2003 Escape with transaxle shudder, drain, flush and refill the transmission fluid with MERCON(R) Multi-Purpose Automatic Transmission Fluid. Then, referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the PCM using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 3. When reprogramming the PCM use blank path programming. Select the proper file from the chart and manually enter the PCM part number or tear tag number to obtain the updated calibration file. To Perform Blank Path Programming: 1. Connect WDS/IDS to vehicle. 2. Select "16 pin", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 5. 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. 6. Screen shows to turn ignition ON. Keep ignition in the "OFF" position, press TICK and you will be asked to cycle the key "ON" and "OFF" a few times. Please keep the key position in the "OFF" position through the key cycles. 7. Screen will show "The diagnostic tester is unable to communicate with this vehicle." You will be prompted to "select a vehicle from the vehicle list", press TICK. 8. A list of vehicles will be displayed, select ALL OTHERS, and press TICK. 9. Screen shows "To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration number (7 digits), Tear Tag number (4 digits), or PCM part number, press TICK. 10. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 11. Follow and answer correctly all remaining screens. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) per Workshop Manual, Section 419-01. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 6702 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9F715 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 6708 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 6709 b. Referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the powertrain control module (PCM) using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 2. If the concern is a 2001 - 2003 Escape with transaxle shudder, drain, flush and refill the transmission fluid with MERCON(R) Multi-Purpose Automatic Transmission Fluid. Then, referring to the calibration charts (Figures 1 and 2), select the applicable file and reprogram the PCM using the TSB Service Procedure and WDS/IDS release B40.5 and higher. Calibration files may also be obtained at the website. 3. When reprogramming the PCM use blank path programming. Select the proper file from the chart and manually enter the PCM part number or tear tag number to obtain the updated calibration file. To Perform Blank Path Programming: 1. Connect WDS/IDS to vehicle. 2. Select "16 pin", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 5. 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. 6. Screen shows to turn ignition ON. Keep ignition in the "OFF" position, press TICK and you will be asked to cycle the key "ON" and "OFF" a few times. Please keep the key position in the "OFF" position through the key cycles. 7. Screen will show "The diagnostic tester is unable to communicate with this vehicle." You will be prompted to "select a vehicle from the vehicle list", press TICK. 8. A list of vehicles will be displayed, select ALL OTHERS, and press TICK. 9. Screen shows "To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration number (7 digits), Tear Tag number (4 digits), or PCM part number, press TICK. 10. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 11. Follow and answer correctly all remaining screens. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) per Workshop Manual, Section 419-01. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 06-11-7 > Jun > 06 > Engine Controls/A/T - Unstable Idle/Shuddering > Page 6710 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9F715 42 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 6714 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 6715 Blower Motor: Testing and Inspection For further information regarding this component please refer to Heating and Air Conditioning; Testing and Inspection. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 6718 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations View 151-18 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 6722 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 6723 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 6724 Blower Motor Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 6725 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 6729 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Air gap between pulley and hub mm (in) 0.35-0.75 (0.014-0.029) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6740 Compressor Clutch: Service Precautions CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6741 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6742 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6743 Compressor Clutch: Testing and Inspection For further information regarding this component please refer to Heating and Air Conditioning; Testing and Inspection. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6744 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6745 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6746 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6747 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6748 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6749 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6753 Compressor Clutch Coil: Service Precautions CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6754 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6755 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6756 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6757 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6758 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 6762 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 6763 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 6764 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 6765 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6772 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6773 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6774 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6775 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6776 Compressor Clutch Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6777 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Service Precautions > Page 6781 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Service Precautions > Page 6782 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Service Precautions > Page 6783 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Service Precautions > Page 6784 Compressor Fitting HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool (5/8 Inch) Disconnect Tool, Spring Lock Coupling Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Service Precautions > Page 6785 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service Precautions > Page 6789 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service Precautions > Page 6790 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service Precautions > Page 6791 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service Precautions > Page 6792 Condenser HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Heater Hose Disconnect Tool Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service Precautions > Page 6793 Special Tool(s) Set, A/C Fittings Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams Control Assembly: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 6797 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 6798 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 6799 Control Assembly: Testing and Inspection For further information regarding this component please refer to Heating and Air Conditioning; Testing and Inspection. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 6802 Control Assembly: Service and Repair Temperature Control Switch REMOVAL 1. Remove the instrument panel center finish panel. 2. Remove the temperature control switch knob. 3. Depress the three tabs and remove the temperature blend door control cable. 4. Remove the temperature control switch. 1 Remove the screw. 2 Depress the tab and rotate the temperature control switch counterclockwise. INSTALLATION Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 6803 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 6804 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 6805 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut Fitting Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut Fitting > Page 6810 Spring Lock Coupling Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Page 6811 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Page 6812 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Page 6813 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 6816 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 6817 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 6818 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 6819 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 6820 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Page 6821 Spring Lock Coupling Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 6825 Evaporator Case: Tools and Equipment Heater Hose Disconnect Tool Spring Lock Coupling Disconnect Tool (5/8 Inch) Disconnect Tool, Spring Lock Coupling Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 6826 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6835 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6836 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6837 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6843 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6844 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6845 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6846 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6847 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6848 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6849 Evaporator Core: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Heater Hose Disconnect Tool Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6850 Special Tool(s) Set, A/C Fittings Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation Evaporator Temperature Sensor/Clutch Cycling Switch: Description and Operation Air Conditioning Evaporator Temperature Sensor A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 1 A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 2 The Air Conditioning Evaporative Temperature (ACET) sensor senses evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance affects the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improving defrost/demist performance, reduce A/C clutch cycling, etc. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams > Page 6857 Expansion Block/Orifice Tube: Service Precautions CAUTION: Plug all ports to prevent contamination from dirt or moisture. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams > Page 6858 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams > Page 6859 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams > Page 6860 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams > Page 6861 4. Remove the special tool. 5. Connect the condenser to evaporator line at the orifice tube. 6. Recharge the A/C system. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams > Page 6862 Expansion Block/Orifice Tube: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations Expansion Valve: Locations For further information regarding this component please refer to: Heating and Air Conditioning; Expansion Block/Orifice Tube. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6874 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6875 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6881 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6882 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service Precautions > Technician Safety Information > Page 6885 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service Precautions > Page 6886 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service Precautions > Page 6887 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service Precautions > Page 6888 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service Precautions > Page 6889 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Description and Operation > Page 6893 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6902 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6903 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6909 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6910 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 6911 Heater Hose: Service and Repair REMOVAL 1. Drain the engine coolant. 2. Disconnect the heater hoses from the heater core. 3. Disconnect the heater outlet hose from the water hose connection. 4. Disconnect the heater hose connection from the engine. 5. Remove the heater hose from the engine compartment. 6. Disconnect the heater hoses from the heater hose junction. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service Precautions High Pressure Safety Valve HVAC: Service Precautions CAUTION: Plug all ports to prevent contamination from dirt or moisture. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service Precautions > Page 6915 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service Precautions > Page 6916 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 manifold and tube assembly bolt and disconnect the A/C manifold and tube. CAUTION: Plug all ports to prevent contamination from dirt or moisture. 6. Remove the A/C compressor pressure relief valve. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service Precautions > Page 6917 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service Precautions > Page 6921 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service Precautions > Page 6922 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation Receiver Dryer: Description and Operation For further information regarding this component please refer to Accumulator HVAC. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Capacity 850 kg (1 lb, 14 oz) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 6930 Refrigerant: Fluid Type Specifications Refrigerant Fluid Type Refrigerant Fluid Type R-134a Refrigerant YN-19 WSH-M17B19-A Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Environmental Impact Information Refrigerant: Environmental Impact Information The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Additional Information Sources For more complete and detailed explanations of the above policies, please refer to: http://www.epa.gov/ozone/ Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/ Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Environmental Impact Information > Page 6933 Fax: 215-541-4635 http://www.macsw.org/ Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Environmental Impact Information > Page 6934 Refrigerant: Vehicle Damage Warnings 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Electronic Leak Detection > Page 6937 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Electronic Leak Detection > Page 6938 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Discharging and Recovery > Page 6941 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Discharging and Recovery > Page 6942 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Discharging and Recovery > Page 6943 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Page 6944 Refrigerant: Tools and Equipment Refrigerent Leak Detector Special Tool(s) Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Page 6945 Delux A/C Refrigerant Analyzer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Capacity 266 ml (9 oz) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 6950 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type Refrigerant Oil Type PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) WSH-M1C231-B Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6951 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6952 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6953 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch > Page 6958 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 6959 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning (A/C) Cycling Switch > Page 6962 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations View 151-18 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6967 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6968 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6969 Blower Motor Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6970 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6974 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6975 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6976 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6977 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6978 Compressor Clutch Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6979 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation Evaporator Temperature Sensor/Clutch Cycling Switch: Description and Operation Air Conditioning Evaporator Temperature Sensor A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 1 A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 2 The Air Conditioning Evaporative Temperature (ACET) sensor senses evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance affects the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improving defrost/demist performance, reduce A/C clutch cycling, etc. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6991 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 6992 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 6995 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 6999 Clutch Cycling Orifice Tube Type Refrigerant System, Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 7000 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Customer Safety Information Vacuum Harness HVAC: Customer Safety Information WARNING: BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON THE PRODUCT LABEL. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Customer Safety Information > Page 7005 Vacuum Harness HVAC: Technician Safety Information WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 7006 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 7007 Vacuum Tester Kit Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7013 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7014 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. 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. 2. Install the new safety belt(s) using the appropriate instructions. Perform the Functional Test. See: Safety Belt Systems/Testing and Inspection/Component Tests and General Diagnostics/Functional Test - Emergency Locking Retractor (ELR) Mode Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7021 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7022 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7023 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7024 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7025 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7026 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Passenger Air Bag Module View 151-19 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Passenger Air Bag Module > Page 7031 Air Bag: Locations Side Air Bag Module View 151-24 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Passenger Air Bag Module > Page 7032 View 151-26 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit > Page 7035 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit > Page 7036 Air Bag: Diagrams Side Air Bag Module Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Technician Safety Information > Page 7039 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Page 7040 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7043 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7044 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7045 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7046 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7047 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7048 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7049 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7050 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7051 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7052 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7053 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7054 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7055 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7056 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7057 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7058 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7059 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7060 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7061 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7062 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7063 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7064 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7065 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7066 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7067 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7068 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7069 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7070 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7071 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7072 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7073 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Page 7074 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations View 151-25 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7078 Air Bag Control Module: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 7081 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 7082 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 7083 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7086 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7087 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7088 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7089 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7090 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7091 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7092 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7093 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7094 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7095 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7096 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7097 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7098 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7099 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7100 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7101 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7102 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7103 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7104 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7105 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7106 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7107 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7108 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Page 7109 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Diagrams Air Bag Sliding Contact: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Technician Safety Information Air Bag Sliding Contact: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Technician Safety Information > Page 7115 Air Bag Sliding Contact: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 7116 Air Bag Sliding Contact: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 7117 Air Bag Sliding Contact: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 7118 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 7119 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 7120 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 7121 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 7122 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 7123 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 7124 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Side Air Bag Sensor, Left View 151-24 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Side Air Bag Sensor, Left > Page 7129 View 151-26 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Air Bag Sensor, Left Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Air Bag Sensor, Left > Page 7132 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 7135 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Page 7136 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7139 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7140 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7141 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7142 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7143 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7144 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7145 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7146 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7147 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7148 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7149 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7150 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7151 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7152 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7153 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7154 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7155 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7156 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7157 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7158 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7159 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7160 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Page 7161 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Side Air Bag Module, Right View 151-26 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Side Air Bag Module, Right > Page 7169 View 151-24 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Diagrams > Side Air Bag Module, Right Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Diagrams > Side Air Bag Module, Right > Page 7172 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Technician Safety Information > Page 7175 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 7176 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 7177 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 7178 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 7179 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 7180 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 7181 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 7182 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 7183 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 7184 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 7185 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 7186 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations View 151-25 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7191 Air Bag Control Module: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 7194 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 7195 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 7196 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7199 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7200 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7201 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7202 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7203 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7204 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7205 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7206 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7207 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7208 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7209 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7210 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7211 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7212 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7213 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7214 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7215 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7216 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7217 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7218 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7219 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7220 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 7221 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Page 7222 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7229 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7230 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7231 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7232 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7233 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7234 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Service Precautions > Page 7239 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Service Precautions > Page 7240 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service Precautions > Customer Safety Information > Page 7265 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service Precautions > Page 7266 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service Precautions > Page 7267 Seat Belt: Testing and Inspection Automatic Locking Retractor (ALR) - Evaluation of Lockability and Release WARNING: 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. 1. Extend the safety belt to latch the tongue into the buckle across an empty seat without slack in the safety belt, with the seat in the full down and rear most position, seat back in an upright position, and if applicable, the D-ring adjusted in the full down position. 2. Pull the shoulder belt to full extension to engage the retractor's Automatic Locking Retractor (ALR) feature. Then allow the belt to retract freely in the ALR mode, and let the retractor force set the proper belt tightness. 3. Pull on the shoulder belt to check that the belt has remained in the ALR mode. If the belt is not locked, install a new belt and retractor assembly. The safety belt should remain locked in the ALR mode across an empty seat. 4. To verify that the safety belt still automatically disengages from the ALR mode properly, with the D-ring adjusted to the full up position, if applicable, unlatch the safety belt tongue from the buckle and allow the safety belt to retract to its stowed position. Pull on the shoulder belt to verify that the retractor assembly has converted automatically out of the ALR mode. If the belt remains locked in the stowed position, a new belt and retractor assembly must be installed. The safety belt should extract freely. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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: The driver side is shown, the passenger side is similar. 1. 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 2. Separate the weather-stripping from the C-pillar. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 7270 3. Remove the safety belt anchor. 1 Using the special tool, remove the bolt. 2 Remove the safety belt anchor. 4. 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. 5. Remove the rear safety belt guide. 1 Using the special tool, remove the bolt. 2 Remove the safety belt guide. 6. Lower the second row seat backrest. 7. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 7271 8. Remove the rear hatch scuff plate. 1 Remove the pin-type retainers. 2 Pull up to release the retaining clips and remove the rear hatch scuff plate. 9. Pull out to release the retaining clips and remove the rear quarter trim panel. 10. Remove the rear safety belt retractor. 1 Using the special tool, remove the bolt. 2 Remove the rear safety belt retractor. INSTALLATION 1. Install the rear safety belt retractor. 1 Position the rear safety belt retractor to the C-pillar. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 7272 2 Using the special tool, install the bolt. 2. 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. 3. Install the rear hatch scuff plate. 1 Align the rear hatch scuff plate and push in, fastening the retainers. 2 Install the pin-type retainers. 4. Install the rear hatch weather-stripping. 5. Install the spacer onto the rear safety belt guide bolt. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 7273 6. 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. 7. 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. 8. Raise the second row seat backrest. 9. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 7274 10. Install the C-pillar weatherstripping. 11. 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. 12. 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/Functional Test - Emergency Locking Retractor (ELR) Mode 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 7275 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. 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/Functional Test - Emergency Locking Retractor (ELR) Mode Safety Belt - Center, Rear Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 7276 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 7277 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 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 RETRACTOR PRETENSIONER OR SAFETY BELT BUCKLE PRETENSIONER. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 7278 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Page 7279 Seat Belt Bolt Bit Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service Precautions > Technician Safety Information > Page 7284 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service Precautions > Page 7285 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 7288 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 7289 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 7290 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 7291 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 7292 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service and Repair > Page 7293 Seat Belt Bolt Bit Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Page 7307 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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/Functional Test - Emergency Locking Retractor (ELR) Mode Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 7316 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 7317 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 7318 D-Ring Installation Kit Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7330 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7336 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service Precautions > Customer Safety Information > Page 7339 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service Precautions > Page 7340 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service Precautions > Page 7341 Seat Belt Retractor: Testing and Inspection Automatic Locking Retractor (ALR) - Evaluation of Lockability and Release WARNING: 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. 1. Extend the safety belt to latch the tongue into the buckle across an empty seat without slack in the safety belt, with the seat in the full down and rear most position, seat back in an upright position, and if applicable, the D-ring adjusted in the full down position. 2. Pull the shoulder belt to full extension to engage the retractor's Automatic Locking Retractor (ALR) feature. Then allow the belt to retract freely in the ALR mode, and let the retractor force set the proper belt tightness. 3. Pull on the shoulder belt to check that the belt has remained in the ALR mode. If the belt is not locked, install a new belt and retractor assembly. The safety belt should remain locked in the ALR mode across an empty seat. 4. To verify that the safety belt still automatically disengages from the ALR mode properly, with the D-ring adjusted to the full up position, if applicable, unlatch the safety belt tongue from the buckle and allow the safety belt to retract to its stowed position. Pull on the shoulder belt to verify that the retractor assembly has converted automatically out of the ALR mode. If the belt remains locked in the stowed position, a new belt and retractor assembly must be installed. The safety belt should extract freely. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 7344 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/Functional Test - Emergency Locking Retractor (ELR) Mode Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 7345 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: The driver side is shown, the passenger side is similar. 1. 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 2. Separate the weather-stripping from the C-pillar. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 7346 3. Remove the safety belt anchor. 1 Using the special tool, remove the bolt. 2 Remove the safety belt anchor. 4. 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. 5. Remove the rear safety belt guide. 1 Using the special tool, remove the bolt. 2 Remove the safety belt guide. 6. Lower the second row seat backrest. 7. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 7347 8. Remove the rear hatch scuff plate. 1 Remove the pin-type retainers. 2 Pull up to release the retaining clips and remove the rear hatch scuff plate. 9. Pull out to release the retaining clips and remove the rear quarter trim panel. 10. Remove the rear safety belt retractor. 1 Using the special tool, remove the bolt. 2 Remove the rear safety belt retractor. INSTALLATION 1. Install the rear safety belt retractor. 1 Position the rear safety belt retractor to the C-pillar. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 7348 2 Using the special tool, install the bolt. 2. 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. 3. Install the rear hatch scuff plate. 1 Align the rear hatch scuff plate and push in, fastening the retainers. 2 Install the pin-type retainers. 4. Install the rear hatch weather-stripping. 5. Install the spacer onto the rear safety belt guide bolt. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 7349 6. 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. 7. 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. 8. Raise the second row seat backrest. 9. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 7350 10. Install the C-pillar weatherstripping. 11. 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. 12. 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/Functional Test - Emergency Locking Retractor (ELR) Mode Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Page 7351 Seat Belt Bolt Bit Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Tensioner > Component Information > Diagrams > Driver Seat Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Tensioner > Component Information > Diagrams > Driver Seat > Page 7356 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Tensioner > Component Information > Service Precautions > Technician Safety Information > Page 7359 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Tensioner > Component Information > Description and Operation > Occupant Restraints - Active > Page 7362 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Tensioner > Component Information > Service and Repair > Occupant Restraints - Active > Page 7365 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Tensioner > Component Information > Service and Repair > Occupant Restraints - Active > Page 7366 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Tensioner > Component Information > Service and Repair > Occupant Restraints - Active > Page 7367 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Tensioner > Component Information > Service and Repair > Occupant Restraints - Active > Page 7368 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 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 RETRACTOR PRETENSIONER OR SAFETY BELT BUCKLE PRETENSIONER. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Tensioner > Component Information > Service and Repair > Occupant Restraints - Active > Page 7369 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Tensioner > Component Information > Service and Repair > Page 7370 Safety Belt Bolt Bit Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Warning Timer > Component Information > Description and Operation Seat Belt Warning Timer: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Air Bag Sensor, Left > Page 7379 View 151-26 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Air Bag Sensor, Left Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Air Bag Sensor, Left > Page 7382 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 7385 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Page 7386 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7389 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7390 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7391 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7392 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7393 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7394 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7395 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7396 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7397 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7398 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7399 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7400 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7401 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7402 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7403 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7404 ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7405 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7406 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7407 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7408 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7409 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 7410 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Page 7411 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Page 7428 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7434 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7435 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7436 View 151-39 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7437 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7438 Accessory Delay Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7439 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair Antenna Cable: Service and Repair 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. INSTALLATION Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Page 7445 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams > Page 7453 Alarm System Transponder: Service and Repair 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. To install, reverse the removal procedure. NOTE: No key replacement or re-initialization needs to occur with the removal or installation of a new PATS transceiver. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7462 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7463 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications Multifunction Electronic Control Modules: Specifications Generic Electronic Module (GEM) Nuts ........................................................................................................................................................ 12 Nm 9 Lb-In Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications > Page 7470 View 151-18 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7473 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7474 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7475 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7476 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7477 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7478 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7479 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7480 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7481 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7482 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7483 Multifunction Electronic Control Modules: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7484 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7485 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7486 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7487 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7488 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7489 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7490 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7491 Multifunction Electronic Control Modules: Connector Views Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7492 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 59-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7493 Diagram 59-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7494 Diagram 59-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description Multifunction Electronic Control Modules: Description and Operation System Description 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description > Page 7497 Multifunction Electronic Control Modules: Description and Operation Principles of Operation (How Does It Work?) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Multifunction Electronic Control Modules: Initial Inspection and Diagnostic Overview 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. ^ 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 Vehicle System to continue diagnostics. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7500 Multifunction Electronic Control Modules: Diagnostic Trouble Code Tests and Associated Procedures DTC Index B1217 - B1304 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7501 DTC Index B1309 - B2141 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7502 DTC Index B2425 - C1962 .. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7503 Symptom Chart Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7504 Multifunction Electronic Control Modules: Pinpoint Tests A1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7505 A1 - A3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7506 A3 - A5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7507 A5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Page 7508 Multifunction Electronic Control Modules: Service and Repair Generic Electronic Module (GEM) REMOVAL 1. Disconnect the battery ground cable. 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Page 7509 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Page 7510 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Audio Control Relay > Component Information > Locations View 151-38 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Audio Control Relay > Component Information > Locations > Page 7518 Accessory Relay (Audio, Instrument Cluster, GEM, & Mirrors) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Audio Control Relay > Component Information > Locations > Page 7519 Audio Control Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Audio Control Relay > Component Information > Locations > Page 7520 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Specifications Speaker: Specifications Subwoofer Enclosure Screws 8 Nm 71 Lb-In Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker Speaker: Diagrams Speaker Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker > Page 7526 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker > Page 7527 Speaker: Diagrams Tweeter Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 7528 Speaker: Description and Operation 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 7529 Speaker: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to: Radio, Stereo, and Compact Disc; Testing and Inspection. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7535 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7536 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7537 View 151-39 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7538 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7539 Accessory Delay Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7540 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Locations View 151-38 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Locations > Page 7547 Accessory Relay (Audio, Instrument Cluster, GEM, & Mirrors) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Locations > Page 7548 Audio Control Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Locations > Page 7549 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications Multifunction Electronic Control Modules: Specifications Generic Electronic Module (GEM) Nuts ........................................................................................................................................................ 12 Nm 9 Lb-In Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications > Page 7553 View 151-18 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7556 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7557 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7558 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7559 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7560 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7561 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7562 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7563 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7564 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7565 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7566 Multifunction Electronic Control Modules: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7567 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7568 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7569 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7570 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7571 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7572 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7573 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7574 Multifunction Electronic Control Modules: Connector Views Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7575 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 59-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7576 Diagram 59-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7577 Diagram 59-3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description Multifunction Electronic Control Modules: Description and Operation System Description 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description > Page 7580 Multifunction Electronic Control Modules: Description and Operation Principles of Operation (How Does It Work?) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Multifunction Electronic Control Modules: Initial Inspection and Diagnostic Overview 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. ^ 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 Vehicle System to continue diagnostics. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7583 Multifunction Electronic Control Modules: Diagnostic Trouble Code Tests and Associated Procedures DTC Index B1217 - B1304 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7584 DTC Index B1309 - B2141 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7585 DTC Index B2425 - C1962 .. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7586 Symptom Chart Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7587 Multifunction Electronic Control Modules: Pinpoint Tests A1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7588 A1 - A3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7589 A3 - A5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7590 A5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Page 7591 Multifunction Electronic Control Modules: Service and Repair Generic Electronic Module (GEM) REMOVAL 1. Disconnect the battery ground cable. 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Page 7592 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Page 7593 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7606 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7607 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7608 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7609 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7610 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7611 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7612 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7613 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7614 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7615 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7616 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7617 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7618 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7619 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7620 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7621 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7622 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7623 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7624 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7625 Diagram 95-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7630 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7631 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7632 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7633 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7634 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7635 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7636 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7637 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7638 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7639 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7640 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7641 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7642 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7643 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7644 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7645 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7646 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7647 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7648 Diagram 95-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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. See: Pinpoint Tests 3. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 21 (10 A) - 16 (10 A) ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7651 Symptom Chart Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7652 Trailer Lamps: Pinpoint Tests Connector Circuit Reference Refer to Vehicle/Diagrams for schematic and connector information. Z1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7653 AA1 - AA2 AC1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7654 AC1 AD1 AE1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7655 AE1 - AE2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7656 73III Automotive Meter Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Page 7657 73III Automotive Meter Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7662 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7663 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7664 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7665 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7666 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7667 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7668 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7669 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7670 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7671 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7672 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7673 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7674 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7675 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7676 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7677 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7678 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7679 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7680 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7681 Diagram 95-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 side). 3. Remove the four front bumper cover bolts (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 7688 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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. Remove the six rear splash shield bolts (three each side). 2. Remove the two rear bumper cover to rear quarter panel screws (one each side). 3. Remove the four pin-type retainers. 4. Remove the rear bumper cover. 1 Remove the screws. 2 Remove the bolts and the liftgate alignment bumpers. 3 Remove the rear bumper cover. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Page 7696 5. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 arms. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 REMOVAL 1. Remove the front door trim panel. 2. Position the watershield aside. 3. If equipped, remove the tie strap from the anti-theft guard. NOTE: The tie strap does not need to be reinstalled. 4. Remove the screws and position the anti-theft guard aside. 5. Release the Clip and disconnect the exterior door handle actuating rod. 6. Remove the anti-theft guard. 7. Remove the exterior door handle screw. 8. Remove the exterior handle actuating rod. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7711 9. Remove the exterior door handle lock cylinder cover. 10. Remove the exterior door handle. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments Front Door Hinge: Adjustments NOTE: Make sure the rear door is within specification before making any adjustments to the front door. Refer to the specification chart. LH and RH sides 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Page 7718 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Page 7719 8. Adjust the front door to specification. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Page 7720 12. Install the A-pillar lower trim panel. 1 Position the A-pillar lower trim panel. 2 Install the pin-type retainers. 13. Install the fender. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Customer Interest for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open Technical Service Bulletin # 02-9-3 Date: 020513 Doors - Unable to Open Article No. 02-9-3 05/13/02 BODY - UNABLE TO OPEN DOORS FORD: 2001-2002 ESCAPE ISSUE Some vehicles built before 12/15/01 may exhibit door latches that will not open. The outside handle and inside handle can be moved freely but latch remains locked. This may occur if the locked door's outside handle is lifted at the same time as the power lock button on either the key fob or the door panel is pressed. ACTION Refer to the follow Service Procedure to open door(s) and replace door latch per Workshop Manual Section 501-14: Handles, Locks, Latches and Entry Systems. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020903A Follow Service Procedure 1.5 Hrs. To Open Door And Replace Door Latch: One Front Door 020903B Follow Service Procedure 2.3 Hrs. To Open Doors And Replace Door Latches: Both Front Doors 020903C Follow Service Procedure 1.8 Hrs. To Open Doors And Replace Door Latches: One Front Door One Rear Door 020903D Follow Service Procedure 2.8 Hrs. To Open Doors And Replace Door Latches: Both Front Doors One Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Customer Interest for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7729 Rear Door 020903E Follow Service Procedure 2.2 Hrs. To Open Doors And Replace Door Latches: One Front Door Both Rear Doors 020903F Follow Service Procedure 0.6 Hr. To Open Door And Replace Door Latch: One Rear Door 020903G Follow Service Procedure 0.9 Hr. To Open Doors And Replace Door Latches: Both Rear Doors 020903H Follow Service Procedure 3.1 Hrs. To Open Doors And Replace Door Latches: Both Front And Both Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 5421813 41 OASIS CODES: 112000 Information Front Door Non-Functional - Latch Replacement Use the procedure below titled "Front Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. Rear Door Non-Functional - Latch Replacement Use the procedure below titled "Rear Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. All Doors Non-Functional - Latch Replacement Use the procedure below titled "All Doors Non-Functional - Latch Replacement" to gain access and replace the failed door latch mechanism. Front Door Non-Functional - Latch Replacement 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. 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. NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR CONNECTOR. WARNING Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Customer Interest for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7730 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. ALL VEHICLES NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. 1. Move the front seat(s) to center position and the affected door glass completely down. 2. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 3. Lower the glove compartment by depressing the locking tabs, and disconnect the passenger air bag module electrical connector and connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 4. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: 5. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 6. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety' belt pretensioner body harness electrical connector. 7. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 8. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 9. Connect the battery ground cable. 10. Remove the front seat rear seat-track to floor nuts. 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. 11. Remove the front seat, front seat-track to floor bolts and remove the seat. 12. Remove the safety belt D-ring cover(s) and bolt(s). 13. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 14. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers ^ Remove the front door scuff plate trim panel(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Customer Interest for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7731 15. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 16. Remove the screw from front door latch release handle bezel and remove bezel. 17. Remove door handle cup screw. CAUTION DO NOT TO SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 18. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Customer Interest for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7732 19. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating lever and pry up (Figure 2, passenger front door shown, all doors similar). CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 20. Open door, and move glass to the up position. 21. Remove last screw and remove and the door trim panel. 22. Remove front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All vehicles: Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 1. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 3. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 4. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 5. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 6. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 7. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Customer Interest for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7733 8. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 9. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 10. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector. Install the driver air bag connector access cover. 11. Remove the special tool from the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector. Close the glove compartment. 12. Connect the battery ground cable. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 13.. Prove out the air bag system. For additional information, refer to section 501-20B: Occupant Restraints - Passive - Supplemental Air Bag System Diagnosis and Testing. 14. Check the restraint system for correct operation. Rear Door Non-Functional - Latch Replacement REMOVAL 1. Remove rear-seat lower cushion(s). All vehicles: 2. Remove door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Position aside water shield. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 4. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems Rear Door Latch Removal and Installation". INSTALLATION 1. Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install rear-seat lower cushion(s). All Doors Non-Functional - Latch Replacement REMOVAL 1. Open tailgate to access rear doors. NOTE REAR DOORS MUST BE OPENED BEFORE FRONT DOORS CAN BE OPENED. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Customer Interest for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7734 2. Remove rear-seat lower cushion(s). All vehicles: 3. Remove rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 4. Position watershield aside. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 5. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems " Rear Door Latch 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 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 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. NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR 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. NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. ALL VEHICLES 6. Move the front seat(s) to center position and the affected door glass into the completely down. 7. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 8. Lower the glove compartment by depressing the locking tabs and disconnect the passenger air bag module electrical connector. Connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 9. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Customer Interest for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7735 10. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 11. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety belt pretensioner body harness electrical connector. 12. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 13. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 14. Connect the battery ground cable. 15. Remove the front seat rear seat-track to floor nuts. 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. 16. Remove the front seat rear seat-track to floor bolts and remove the seat through rear doors. 17. Remove the safety belt D-ring cover(s) and bolt(s). 18. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 19. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers ^ Remove the front door scuff plate trim panel(s) 20. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 21. Remove the screw from front door latch release handle bezel and remove bezel. 22. Remove door handle cup screw. CAUTION DO NOT SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 23. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. 24. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating fever and pry up (Figure 2, passenger front door shown, all doors similar). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Customer Interest for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7736 CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 25. Open door(s), and move glass to the up position. 26. Remove last screw and remove and the door trim panel(s). 27. Remove door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All Vehicles: 1. Install new rear door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 4. Install rear-seat lower cushion(s). 5. Install new front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 6. Install front door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 7. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 8. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 9. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 10. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 11. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. 12. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 13. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 14. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector, and install the driver air bag connector access cover. 15. Remove the special tool to the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector, and close the glove compartment. 16. Connect the battery ground cable. For additional information, refer to section 414-01: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Customer Interest for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7737 Battery, Mounting and Cables General Procedures "Battery Disconnect". 17. Prove out the air bag system. For additional information, refer to section 501-2DB: Occupant Restraints Passive - Supplemental Air Bag System Diagnosis and Testing. 18. Check the restraint system for correct operation. 19. Close tailgate. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open Technical Service Bulletin # 02-9-3 Date: 020513 Doors - Unable to Open Article No. 02-9-3 05/13/02 BODY - UNABLE TO OPEN DOORS FORD: 2001-2002 ESCAPE ISSUE Some vehicles built before 12/15/01 may exhibit door latches that will not open. The outside handle and inside handle can be moved freely but latch remains locked. This may occur if the locked door's outside handle is lifted at the same time as the power lock button on either the key fob or the door panel is pressed. ACTION Refer to the follow Service Procedure to open door(s) and replace door latch per Workshop Manual Section 501-14: Handles, Locks, Latches and Entry Systems. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020903A Follow Service Procedure 1.5 Hrs. To Open Door And Replace Door Latch: One Front Door 020903B Follow Service Procedure 2.3 Hrs. To Open Doors And Replace Door Latches: Both Front Doors 020903C Follow Service Procedure 1.8 Hrs. To Open Doors And Replace Door Latches: One Front Door One Rear Door 020903D Follow Service Procedure 2.8 Hrs. To Open Doors And Replace Door Latches: Both Front Doors One Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7743 Rear Door 020903E Follow Service Procedure 2.2 Hrs. To Open Doors And Replace Door Latches: One Front Door Both Rear Doors 020903F Follow Service Procedure 0.6 Hr. To Open Door And Replace Door Latch: One Rear Door 020903G Follow Service Procedure 0.9 Hr. To Open Doors And Replace Door Latches: Both Rear Doors 020903H Follow Service Procedure 3.1 Hrs. To Open Doors And Replace Door Latches: Both Front And Both Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 5421813 41 OASIS CODES: 112000 Information Front Door Non-Functional - Latch Replacement Use the procedure below titled "Front Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. Rear Door Non-Functional - Latch Replacement Use the procedure below titled "Rear Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. All Doors Non-Functional - Latch Replacement Use the procedure below titled "All Doors Non-Functional - Latch Replacement" to gain access and replace the failed door latch mechanism. Front Door Non-Functional - Latch Replacement 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. 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. NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR CONNECTOR. WARNING Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7744 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. ALL VEHICLES NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. 1. Move the front seat(s) to center position and the affected door glass completely down. 2. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 3. Lower the glove compartment by depressing the locking tabs, and disconnect the passenger air bag module electrical connector and connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 4. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: 5. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 6. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety' belt pretensioner body harness electrical connector. 7. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 8. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 9. Connect the battery ground cable. 10. Remove the front seat rear seat-track to floor nuts. 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. 11. Remove the front seat, front seat-track to floor bolts and remove the seat. 12. Remove the safety belt D-ring cover(s) and bolt(s). 13. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 14. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers ^ Remove the front door scuff plate trim panel(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7745 15. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 16. Remove the screw from front door latch release handle bezel and remove bezel. 17. Remove door handle cup screw. CAUTION DO NOT TO SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 18. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7746 19. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating lever and pry up (Figure 2, passenger front door shown, all doors similar). CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 20. Open door, and move glass to the up position. 21. Remove last screw and remove and the door trim panel. 22. Remove front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All vehicles: Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 1. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 3. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 4. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 5. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 6. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 7. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7747 8. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 9. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 10. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector. Install the driver air bag connector access cover. 11. Remove the special tool from the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector. Close the glove compartment. 12. Connect the battery ground cable. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 13.. Prove out the air bag system. For additional information, refer to section 501-20B: Occupant Restraints - Passive - Supplemental Air Bag System Diagnosis and Testing. 14. Check the restraint system for correct operation. Rear Door Non-Functional - Latch Replacement REMOVAL 1. Remove rear-seat lower cushion(s). All vehicles: 2. Remove door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Position aside water shield. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 4. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems Rear Door Latch Removal and Installation". INSTALLATION 1. Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install rear-seat lower cushion(s). All Doors Non-Functional - Latch Replacement REMOVAL 1. Open tailgate to access rear doors. NOTE REAR DOORS MUST BE OPENED BEFORE FRONT DOORS CAN BE OPENED. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7748 2. Remove rear-seat lower cushion(s). All vehicles: 3. Remove rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 4. Position watershield aside. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 5. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems " Rear Door Latch 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 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 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. NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR 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. NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. ALL VEHICLES 6. Move the front seat(s) to center position and the affected door glass into the completely down. 7. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 8. Lower the glove compartment by depressing the locking tabs and disconnect the passenger air bag module electrical connector. Connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 9. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7749 10. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 11. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety belt pretensioner body harness electrical connector. 12. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 13. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 14. Connect the battery ground cable. 15. Remove the front seat rear seat-track to floor nuts. 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. 16. Remove the front seat rear seat-track to floor bolts and remove the seat through rear doors. 17. Remove the safety belt D-ring cover(s) and bolt(s). 18. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 19. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers ^ Remove the front door scuff plate trim panel(s) 20. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 21. Remove the screw from front door latch release handle bezel and remove bezel. 22. Remove door handle cup screw. CAUTION DO NOT SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 23. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. 24. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating fever and pry up (Figure 2, passenger front door shown, all doors similar). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7750 CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 25. Open door(s), and move glass to the up position. 26. Remove last screw and remove and the door trim panel(s). 27. Remove door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All Vehicles: 1. Install new rear door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 4. Install rear-seat lower cushion(s). 5. Install new front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 6. Install front door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 7. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 8. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 9. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 10. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 11. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. 12. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 13. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 14. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector, and install the driver air bag connector access cover. 15. Remove the special tool to the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector, and close the glove compartment. 16. Connect the battery ground cable. For additional information, refer to section 414-01: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7751 Battery, Mounting and Cables General Procedures "Battery Disconnect". 17. Prove out the air bag system. For additional information, refer to section 501-2DB: Occupant Restraints Passive - Supplemental Air Bag System Diagnosis and Testing. 18. Check the restraint system for correct operation. 19. Close tailgate. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7752 Front Door Latch: By Symptom Technical Service Bulletin # 02-9-3 Date: 020513 Doors - Unable to Open Article No. 02-9-3 05/13/02 BODY - UNABLE TO OPEN DOORS FORD: 2001-2002 ESCAPE ISSUE Some vehicles built before 12/15/01 may exhibit door latches that will not open. The outside handle and inside handle can be moved freely but latch remains locked. This may occur if the locked door's outside handle is lifted at the same time as the power lock button on either the key fob or the door panel is pressed. ACTION Refer to the follow Service Procedure to open door(s) and replace door latch per Workshop Manual Section 501-14: Handles, Locks, Latches and Entry Systems. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020903A Follow Service Procedure 1.5 Hrs. To Open Door And Replace Door Latch: One Front Door 020903B Follow Service Procedure 2.3 Hrs. To Open Doors And Replace Door Latches: Both Front Doors 020903C Follow Service Procedure 1.8 Hrs. To Open Doors And Replace Door Latches: One Front Door One Rear Door 020903D Follow Service Procedure 2.8 Hrs. To Open Doors And Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7753 Replace Door Latches: Both Front Doors One Rear Door 020903E Follow Service Procedure 2.2 Hrs. To Open Doors And Replace Door Latches: One Front Door Both Rear Doors 020903F Follow Service Procedure 0.6 Hr. To Open Door And Replace Door Latch: One Rear Door 020903G Follow Service Procedure 0.9 Hr. To Open Doors And Replace Door Latches: Both Rear Doors 020903H Follow Service Procedure 3.1 Hrs. To Open Doors And Replace Door Latches: Both Front And Both Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 5421813 41 OASIS CODES: 112000 Information Front Door Non-Functional - Latch Replacement Use the procedure below titled "Front Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. Rear Door Non-Functional - Latch Replacement Use the procedure below titled "Rear Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. All Doors Non-Functional - Latch Replacement Use the procedure below titled "All Doors Non-Functional - Latch Replacement" to gain access and replace the failed door latch mechanism. Front Door Non-Functional - Latch Replacement 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. 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. NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR CONNECTOR. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7754 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. ALL VEHICLES NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. 1. Move the front seat(s) to center position and the affected door glass completely down. 2. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 3. Lower the glove compartment by depressing the locking tabs, and disconnect the passenger air bag module electrical connector and connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 4. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: 5. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 6. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety' belt pretensioner body harness electrical connector. 7. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 8. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 9. Connect the battery ground cable. 10. Remove the front seat rear seat-track to floor nuts. 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. 11. Remove the front seat, front seat-track to floor bolts and remove the seat. 12. Remove the safety belt D-ring cover(s) and bolt(s). 13. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 14. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers ^ Remove the front door scuff plate trim panel(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7755 15. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 16. Remove the screw from front door latch release handle bezel and remove bezel. 17. Remove door handle cup screw. CAUTION DO NOT TO SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 18. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7756 19. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating lever and pry up (Figure 2, passenger front door shown, all doors similar). CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 20. Open door, and move glass to the up position. 21. Remove last screw and remove and the door trim panel. 22. Remove front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All vehicles: Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 1. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 3. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 4. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 5. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 6. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 7. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7757 8. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 9. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 10. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector. Install the driver air bag connector access cover. 11. Remove the special tool from the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector. Close the glove compartment. 12. Connect the battery ground cable. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 13.. Prove out the air bag system. For additional information, refer to section 501-20B: Occupant Restraints - Passive - Supplemental Air Bag System Diagnosis and Testing. 14. Check the restraint system for correct operation. Rear Door Non-Functional - Latch Replacement REMOVAL 1. Remove rear-seat lower cushion(s). All vehicles: 2. Remove door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Position aside water shield. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 4. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems Rear Door Latch Removal and Installation". INSTALLATION 1. Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install rear-seat lower cushion(s). All Doors Non-Functional - Latch Replacement REMOVAL 1. Open tailgate to access rear doors. NOTE REAR DOORS MUST BE OPENED BEFORE FRONT DOORS CAN BE OPENED. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7758 2. Remove rear-seat lower cushion(s). All vehicles: 3. Remove rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 4. Position watershield aside. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 5. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems " Rear Door Latch 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 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 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. NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR 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. NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. ALL VEHICLES 6. Move the front seat(s) to center position and the affected door glass into the completely down. 7. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 8. Lower the glove compartment by depressing the locking tabs and disconnect the passenger air bag module electrical connector. Connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 9. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7759 10. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 11. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety belt pretensioner body harness electrical connector. 12. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 13. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 14. Connect the battery ground cable. 15. Remove the front seat rear seat-track to floor nuts. 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. 16. Remove the front seat rear seat-track to floor bolts and remove the seat through rear doors. 17. Remove the safety belt D-ring cover(s) and bolt(s). 18. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 19. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers ^ Remove the front door scuff plate trim panel(s) 20. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 21. Remove the screw from front door latch release handle bezel and remove bezel. 22. Remove door handle cup screw. CAUTION DO NOT SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 23. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. 24. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating fever and pry up (Figure 2, passenger front door shown, all doors similar). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7760 CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 25. Open door(s), and move glass to the up position. 26. Remove last screw and remove and the door trim panel(s). 27. Remove door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All Vehicles: 1. Install new rear door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 4. Install rear-seat lower cushion(s). 5. Install new front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 6. Install front door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 7. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 8. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 9. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 10. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 11. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. 12. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 13. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 14. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector, and install the driver air bag connector access cover. 15. Remove the special tool to the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector, and close the glove compartment. 16. Connect the battery ground cable. For additional information, refer to section 414-01: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7761 Battery, Mounting and Cables General Procedures "Battery Disconnect". 17. Prove out the air bag system. For additional information, refer to section 501-2DB: Occupant Restraints Passive - Supplemental Air Bag System Diagnosis and Testing. 18. Check the restraint system for correct operation. 19. Close tailgate. Technical Service Bulletin # 02-9-3 Date: 020513 Doors - Unable to Open Article No. 02-9-3 05/13/02 BODY - UNABLE TO OPEN DOORS FORD: 2001-2002 ESCAPE ISSUE Some vehicles built before 12/15/01 may exhibit door latches that will not open. The outside handle and inside handle can be moved freely but latch remains locked. This may occur if the locked door's outside handle is lifted at the same time as the power lock button on either the key fob or the door panel is pressed. ACTION Refer to the follow Service Procedure to open door(s) and replace door latch per Workshop Manual Section 501-14: Handles, Locks, Latches and Entry Systems. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020903A Follow Service Procedure 1.5 Hrs. To Open Door And Replace Door Latch: One Front Door 020903B Follow Service Procedure 2.3 Hrs. To Open Doors And Replace Door Latches: Both Front Doors 020903C Follow Service Procedure 1.8 Hrs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7762 To Open Doors And Replace Door Latches: One Front Door One Rear Door 020903D Follow Service Procedure 2.8 Hrs. To Open Doors And Replace Door Latches: Both Front Doors One Rear Door 020903E Follow Service Procedure 2.2 Hrs. To Open Doors And Replace Door Latches: One Front Door Both Rear Doors 020903F Follow Service Procedure 0.6 Hr. To Open Door And Replace Door Latch: One Rear Door 020903G Follow Service Procedure 0.9 Hr. To Open Doors And Replace Door Latches: Both Rear Doors 020903H Follow Service Procedure 3.1 Hrs. To Open Doors And Replace Door Latches: Both Front And Both Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 5421813 41 OASIS CODES: 112000 Information Front Door Non-Functional - Latch Replacement Use the procedure below titled "Front Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. Rear Door Non-Functional - Latch Replacement Use the procedure below titled "Rear Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. All Doors Non-Functional - Latch Replacement Use the procedure below titled "All Doors Non-Functional - Latch Replacement" to gain access and replace the failed door latch mechanism. Front Door Non-Functional - Latch Replacement 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7763 NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR 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. ALL VEHICLES NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. 1. Move the front seat(s) to center position and the affected door glass completely down. 2. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 3. Lower the glove compartment by depressing the locking tabs, and disconnect the passenger air bag module electrical connector and connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 4. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: 5. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 6. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety' belt pretensioner body harness electrical connector. 7. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 8. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 9. Connect the battery ground cable. 10. Remove the front seat rear seat-track to floor nuts. 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. 11. Remove the front seat, front seat-track to floor bolts and remove the seat. 12. Remove the safety belt D-ring cover(s) and bolt(s). 13. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 14. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7764 ^ Remove the front door scuff plate trim panel(s) 15. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 16. Remove the screw from front door latch release handle bezel and remove bezel. 17. Remove door handle cup screw. CAUTION DO NOT TO SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 18. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7765 19. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating lever and pry up (Figure 2, passenger front door shown, all doors similar). CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 20. Open door, and move glass to the up position. 21. Remove last screw and remove and the door trim panel. 22. Remove front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All vehicles: Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 1. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 3. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 4. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 5. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 6. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 7. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7766 8. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 9. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 10. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector. Install the driver air bag connector access cover. 11. Remove the special tool from the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector. Close the glove compartment. 12. Connect the battery ground cable. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 13.. Prove out the air bag system. For additional information, refer to section 501-20B: Occupant Restraints - Passive - Supplemental Air Bag System Diagnosis and Testing. 14. Check the restraint system for correct operation. Rear Door Non-Functional - Latch Replacement REMOVAL 1. Remove rear-seat lower cushion(s). All vehicles: 2. Remove door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Position aside water shield. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 4. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems Rear Door Latch Removal and Installation". INSTALLATION 1. Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install rear-seat lower cushion(s). All Doors Non-Functional - Latch Replacement REMOVAL 1. Open tailgate to access rear doors. NOTE REAR DOORS MUST BE OPENED BEFORE FRONT DOORS CAN BE OPENED. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7767 2. Remove rear-seat lower cushion(s). All vehicles: 3. Remove rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 4. Position watershield aside. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 5. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems " Rear Door Latch 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 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 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. NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR 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. NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. ALL VEHICLES 6. Move the front seat(s) to center position and the affected door glass into the completely down. 7. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 8. Lower the glove compartment by depressing the locking tabs and disconnect the passenger air bag module electrical connector. Connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 9. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7768 10. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 11. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety belt pretensioner body harness electrical connector. 12. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 13. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 14. Connect the battery ground cable. 15. Remove the front seat rear seat-track to floor nuts. 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. 16. Remove the front seat rear seat-track to floor bolts and remove the seat through rear doors. 17. Remove the safety belt D-ring cover(s) and bolt(s). 18. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 19. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers ^ Remove the front door scuff plate trim panel(s) 20. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 21. Remove the screw from front door latch release handle bezel and remove bezel. 22. Remove door handle cup screw. CAUTION DO NOT SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 23. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. 24. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating fever and pry up (Figure 2, passenger front door shown, all doors similar). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7769 CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 25. Open door(s), and move glass to the up position. 26. Remove last screw and remove and the door trim panel(s). 27. Remove door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All Vehicles: 1. Install new rear door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 4. Install rear-seat lower cushion(s). 5. Install new front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 6. Install front door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 7. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 8. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 9. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 10. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 11. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. 12. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 13. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 14. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector, and install the driver air bag connector access cover. 15. Remove the special tool to the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector, and close the glove compartment. 16. Connect the battery ground cable. For additional information, refer to section 414-01: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Latch: > Page 7770 Battery, Mounting and Cables General Procedures "Battery Disconnect". 17. Prove out the air bag system. For additional information, refer to section 501-2DB: Occupant Restraints Passive - Supplemental Air Bag System Diagnosis and Testing. 18. Check the restraint system for correct operation. 19. Close tailgate. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Page 7771 Front Door Latch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Position the watershield aside. 3. Position the interior door handle aside. ^ Release the clip. 4. If equipped, remove the tie strap from the anti-theft guard. NOTE: The tie strap does not need to be reinstalled. 5. Remove the screws and position the anti-theft guard aside. 6. Release the clip and disconnect the exterior door handle actuating rod. 7. Remove the anti-theft guard. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Page 7772 8. Remove and discard the door latch screws. 9. Disconnect the door latch electrical connector. 1 Release the clip. 2 Disconnect the electrical connector. 10. Remove the front door latch. ^ Disconnect the lock cylinder rod. 11. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 REMOVAL Vehicles with power windows 1. Disconnect the battery ground cable. Vehicles with manual windows 2. Remove the front door manual window regulator handle. 1 Release the clip. 2 Remove the front door manual window regulator handle. All vehicles 3. Remove the front door latch release handle bezel. 1 Remove the screw. 2 Remove the front door latch release handle bezel. 4. Remove the door handle cup screw. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 7776 5. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments 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. Check the adjustment. Repeat the procedure as necessary. NOTE: The rear door is shown, the front door is similar. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Page 7783 9. Remove the front door window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Left Front Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Left Front > Page 7788 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 7792 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7798 6. Remove the exterior door handle screws. 7. Remove the exterior door handle. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Adjustments Rear Door Hinge: Adjustments 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 to specification. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Adjustments > Page 7805 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Customer Interest for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open Technical Service Bulletin # 02-9-3 Date: 020513 Doors - Unable to Open Article No. 02-9-3 05/13/02 BODY - UNABLE TO OPEN DOORS FORD: 2001-2002 ESCAPE ISSUE Some vehicles built before 12/15/01 may exhibit door latches that will not open. The outside handle and inside handle can be moved freely but latch remains locked. This may occur if the locked door's outside handle is lifted at the same time as the power lock button on either the key fob or the door panel is pressed. ACTION Refer to the follow Service Procedure to open door(s) and replace door latch per Workshop Manual Section 501-14: Handles, Locks, Latches and Entry Systems. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020903A Follow Service Procedure 1.5 Hrs. To Open Door And Replace Door Latch: One Front Door 020903B Follow Service Procedure 2.3 Hrs. To Open Doors And Replace Door Latches: Both Front Doors 020903C Follow Service Procedure 1.8 Hrs. To Open Doors And Replace Door Latches: One Front Door One Rear Door 020903D Follow Service Procedure 2.8 Hrs. To Open Doors And Replace Door Latches: Both Front Doors One Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Customer Interest for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7814 Rear Door 020903E Follow Service Procedure 2.2 Hrs. To Open Doors And Replace Door Latches: One Front Door Both Rear Doors 020903F Follow Service Procedure 0.6 Hr. To Open Door And Replace Door Latch: One Rear Door 020903G Follow Service Procedure 0.9 Hr. To Open Doors And Replace Door Latches: Both Rear Doors 020903H Follow Service Procedure 3.1 Hrs. To Open Doors And Replace Door Latches: Both Front And Both Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 5421813 41 OASIS CODES: 112000 Information Front Door Non-Functional - Latch Replacement Use the procedure below titled "Front Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. Rear Door Non-Functional - Latch Replacement Use the procedure below titled "Rear Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. All Doors Non-Functional - Latch Replacement Use the procedure below titled "All Doors Non-Functional - Latch Replacement" to gain access and replace the failed door latch mechanism. Front Door Non-Functional - Latch Replacement 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. 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. NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR CONNECTOR. WARNING Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Customer Interest for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7815 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. ALL VEHICLES NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. 1. Move the front seat(s) to center position and the affected door glass completely down. 2. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 3. Lower the glove compartment by depressing the locking tabs, and disconnect the passenger air bag module electrical connector and connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 4. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: 5. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 6. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety' belt pretensioner body harness electrical connector. 7. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 8. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 9. Connect the battery ground cable. 10. Remove the front seat rear seat-track to floor nuts. 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. 11. Remove the front seat, front seat-track to floor bolts and remove the seat. 12. Remove the safety belt D-ring cover(s) and bolt(s). 13. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 14. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers ^ Remove the front door scuff plate trim panel(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Customer Interest for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7816 15. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 16. Remove the screw from front door latch release handle bezel and remove bezel. 17. Remove door handle cup screw. CAUTION DO NOT TO SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 18. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Customer Interest for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7817 19. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating lever and pry up (Figure 2, passenger front door shown, all doors similar). CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 20. Open door, and move glass to the up position. 21. Remove last screw and remove and the door trim panel. 22. Remove front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All vehicles: Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 1. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 3. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 4. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 5. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 6. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 7. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Customer Interest for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7818 8. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 9. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 10. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector. Install the driver air bag connector access cover. 11. Remove the special tool from the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector. Close the glove compartment. 12. Connect the battery ground cable. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 13.. Prove out the air bag system. For additional information, refer to section 501-20B: Occupant Restraints - Passive - Supplemental Air Bag System Diagnosis and Testing. 14. Check the restraint system for correct operation. Rear Door Non-Functional - Latch Replacement REMOVAL 1. Remove rear-seat lower cushion(s). All vehicles: 2. Remove door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Position aside water shield. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 4. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems Rear Door Latch Removal and Installation". INSTALLATION 1. Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install rear-seat lower cushion(s). All Doors Non-Functional - Latch Replacement REMOVAL 1. Open tailgate to access rear doors. NOTE REAR DOORS MUST BE OPENED BEFORE FRONT DOORS CAN BE OPENED. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Customer Interest for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7819 2. Remove rear-seat lower cushion(s). All vehicles: 3. Remove rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 4. Position watershield aside. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 5. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems " Rear Door Latch 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 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 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. NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR 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. NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. ALL VEHICLES 6. Move the front seat(s) to center position and the affected door glass into the completely down. 7. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 8. Lower the glove compartment by depressing the locking tabs and disconnect the passenger air bag module electrical connector. Connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 9. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Customer Interest for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7820 10. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 11. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety belt pretensioner body harness electrical connector. 12. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 13. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 14. Connect the battery ground cable. 15. Remove the front seat rear seat-track to floor nuts. 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. 16. Remove the front seat rear seat-track to floor bolts and remove the seat through rear doors. 17. Remove the safety belt D-ring cover(s) and bolt(s). 18. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 19. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers ^ Remove the front door scuff plate trim panel(s) 20. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 21. Remove the screw from front door latch release handle bezel and remove bezel. 22. Remove door handle cup screw. CAUTION DO NOT SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 23. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. 24. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating fever and pry up (Figure 2, passenger front door shown, all doors similar). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Customer Interest for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7821 CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 25. Open door(s), and move glass to the up position. 26. Remove last screw and remove and the door trim panel(s). 27. Remove door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All Vehicles: 1. Install new rear door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 4. Install rear-seat lower cushion(s). 5. Install new front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 6. Install front door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 7. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 8. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 9. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 10. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 11. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. 12. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 13. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 14. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector, and install the driver air bag connector access cover. 15. Remove the special tool to the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector, and close the glove compartment. 16. Connect the battery ground cable. For additional information, refer to section 414-01: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Customer Interest for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7822 Battery, Mounting and Cables General Procedures "Battery Disconnect". 17. Prove out the air bag system. For additional information, refer to section 501-2DB: Occupant Restraints Passive - Supplemental Air Bag System Diagnosis and Testing. 18. Check the restraint system for correct operation. 19. Close tailgate. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open Technical Service Bulletin # 02-9-3 Date: 020513 Doors - Unable to Open Article No. 02-9-3 05/13/02 BODY - UNABLE TO OPEN DOORS FORD: 2001-2002 ESCAPE ISSUE Some vehicles built before 12/15/01 may exhibit door latches that will not open. The outside handle and inside handle can be moved freely but latch remains locked. This may occur if the locked door's outside handle is lifted at the same time as the power lock button on either the key fob or the door panel is pressed. ACTION Refer to the follow Service Procedure to open door(s) and replace door latch per Workshop Manual Section 501-14: Handles, Locks, Latches and Entry Systems. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020903A Follow Service Procedure 1.5 Hrs. To Open Door And Replace Door Latch: One Front Door 020903B Follow Service Procedure 2.3 Hrs. To Open Doors And Replace Door Latches: Both Front Doors 020903C Follow Service Procedure 1.8 Hrs. To Open Doors And Replace Door Latches: One Front Door One Rear Door 020903D Follow Service Procedure 2.8 Hrs. To Open Doors And Replace Door Latches: Both Front Doors One Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7828 Rear Door 020903E Follow Service Procedure 2.2 Hrs. To Open Doors And Replace Door Latches: One Front Door Both Rear Doors 020903F Follow Service Procedure 0.6 Hr. To Open Door And Replace Door Latch: One Rear Door 020903G Follow Service Procedure 0.9 Hr. To Open Doors And Replace Door Latches: Both Rear Doors 020903H Follow Service Procedure 3.1 Hrs. To Open Doors And Replace Door Latches: Both Front And Both Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 5421813 41 OASIS CODES: 112000 Information Front Door Non-Functional - Latch Replacement Use the procedure below titled "Front Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. Rear Door Non-Functional - Latch Replacement Use the procedure below titled "Rear Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. All Doors Non-Functional - Latch Replacement Use the procedure below titled "All Doors Non-Functional - Latch Replacement" to gain access and replace the failed door latch mechanism. Front Door Non-Functional - Latch Replacement 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. 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. NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR CONNECTOR. WARNING Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7829 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. ALL VEHICLES NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. 1. Move the front seat(s) to center position and the affected door glass completely down. 2. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 3. Lower the glove compartment by depressing the locking tabs, and disconnect the passenger air bag module electrical connector and connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 4. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: 5. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 6. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety' belt pretensioner body harness electrical connector. 7. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 8. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 9. Connect the battery ground cable. 10. Remove the front seat rear seat-track to floor nuts. 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. 11. Remove the front seat, front seat-track to floor bolts and remove the seat. 12. Remove the safety belt D-ring cover(s) and bolt(s). 13. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 14. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers ^ Remove the front door scuff plate trim panel(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7830 15. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 16. Remove the screw from front door latch release handle bezel and remove bezel. 17. Remove door handle cup screw. CAUTION DO NOT TO SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 18. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7831 19. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating lever and pry up (Figure 2, passenger front door shown, all doors similar). CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 20. Open door, and move glass to the up position. 21. Remove last screw and remove and the door trim panel. 22. Remove front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All vehicles: Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 1. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 3. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 4. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 5. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 6. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 7. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7832 8. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 9. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 10. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector. Install the driver air bag connector access cover. 11. Remove the special tool from the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector. Close the glove compartment. 12. Connect the battery ground cable. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 13.. Prove out the air bag system. For additional information, refer to section 501-20B: Occupant Restraints - Passive - Supplemental Air Bag System Diagnosis and Testing. 14. Check the restraint system for correct operation. Rear Door Non-Functional - Latch Replacement REMOVAL 1. Remove rear-seat lower cushion(s). All vehicles: 2. Remove door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Position aside water shield. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 4. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems Rear Door Latch Removal and Installation". INSTALLATION 1. Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install rear-seat lower cushion(s). All Doors Non-Functional - Latch Replacement REMOVAL 1. Open tailgate to access rear doors. NOTE REAR DOORS MUST BE OPENED BEFORE FRONT DOORS CAN BE OPENED. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7833 2. Remove rear-seat lower cushion(s). All vehicles: 3. Remove rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 4. Position watershield aside. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 5. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems " Rear Door Latch 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 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 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. NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR 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. NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. ALL VEHICLES 6. Move the front seat(s) to center position and the affected door glass into the completely down. 7. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 8. Lower the glove compartment by depressing the locking tabs and disconnect the passenger air bag module electrical connector. Connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 9. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7834 10. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 11. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety belt pretensioner body harness electrical connector. 12. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 13. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 14. Connect the battery ground cable. 15. Remove the front seat rear seat-track to floor nuts. 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. 16. Remove the front seat rear seat-track to floor bolts and remove the seat through rear doors. 17. Remove the safety belt D-ring cover(s) and bolt(s). 18. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 19. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers ^ Remove the front door scuff plate trim panel(s) 20. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 21. Remove the screw from front door latch release handle bezel and remove bezel. 22. Remove door handle cup screw. CAUTION DO NOT SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 23. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. 24. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating fever and pry up (Figure 2, passenger front door shown, all doors similar). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7835 CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 25. Open door(s), and move glass to the up position. 26. Remove last screw and remove and the door trim panel(s). 27. Remove door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All Vehicles: 1. Install new rear door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 4. Install rear-seat lower cushion(s). 5. Install new front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 6. Install front door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 7. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 8. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 9. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 10. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 11. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. 12. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 13. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 14. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector, and install the driver air bag connector access cover. 15. Remove the special tool to the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector, and close the glove compartment. 16. Connect the battery ground cable. For additional information, refer to section 414-01: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > 02-9-3 > May > 02 > Doors - Unable to Open > Page 7836 Battery, Mounting and Cables General Procedures "Battery Disconnect". 17. Prove out the air bag system. For additional information, refer to section 501-2DB: Occupant Restraints Passive - Supplemental Air Bag System Diagnosis and Testing. 18. Check the restraint system for correct operation. 19. Close tailgate. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7837 Rear Door Latch: By Symptom Technical Service Bulletin # 02-9-3 Date: 020513 Doors - Unable to Open Article No. 02-9-3 05/13/02 BODY - UNABLE TO OPEN DOORS FORD: 2001-2002 ESCAPE ISSUE Some vehicles built before 12/15/01 may exhibit door latches that will not open. The outside handle and inside handle can be moved freely but latch remains locked. This may occur if the locked door's outside handle is lifted at the same time as the power lock button on either the key fob or the door panel is pressed. ACTION Refer to the follow Service Procedure to open door(s) and replace door latch per Workshop Manual Section 501-14: Handles, Locks, Latches and Entry Systems. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020903A Follow Service Procedure 1.5 Hrs. To Open Door And Replace Door Latch: One Front Door 020903B Follow Service Procedure 2.3 Hrs. To Open Doors And Replace Door Latches: Both Front Doors 020903C Follow Service Procedure 1.8 Hrs. To Open Doors And Replace Door Latches: One Front Door One Rear Door 020903D Follow Service Procedure 2.8 Hrs. To Open Doors And Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7838 Replace Door Latches: Both Front Doors One Rear Door 020903E Follow Service Procedure 2.2 Hrs. To Open Doors And Replace Door Latches: One Front Door Both Rear Doors 020903F Follow Service Procedure 0.6 Hr. To Open Door And Replace Door Latch: One Rear Door 020903G Follow Service Procedure 0.9 Hr. To Open Doors And Replace Door Latches: Both Rear Doors 020903H Follow Service Procedure 3.1 Hrs. To Open Doors And Replace Door Latches: Both Front And Both Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 5421813 41 OASIS CODES: 112000 Information Front Door Non-Functional - Latch Replacement Use the procedure below titled "Front Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. Rear Door Non-Functional - Latch Replacement Use the procedure below titled "Rear Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. All Doors Non-Functional - Latch Replacement Use the procedure below titled "All Doors Non-Functional - Latch Replacement" to gain access and replace the failed door latch mechanism. Front Door Non-Functional - Latch Replacement 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. 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. NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR CONNECTOR. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7839 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. ALL VEHICLES NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. 1. Move the front seat(s) to center position and the affected door glass completely down. 2. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 3. Lower the glove compartment by depressing the locking tabs, and disconnect the passenger air bag module electrical connector and connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 4. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: 5. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 6. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety' belt pretensioner body harness electrical connector. 7. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 8. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 9. Connect the battery ground cable. 10. Remove the front seat rear seat-track to floor nuts. 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. 11. Remove the front seat, front seat-track to floor bolts and remove the seat. 12. Remove the safety belt D-ring cover(s) and bolt(s). 13. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 14. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers ^ Remove the front door scuff plate trim panel(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7840 15. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 16. Remove the screw from front door latch release handle bezel and remove bezel. 17. Remove door handle cup screw. CAUTION DO NOT TO SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 18. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7841 19. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating lever and pry up (Figure 2, passenger front door shown, all doors similar). CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 20. Open door, and move glass to the up position. 21. Remove last screw and remove and the door trim panel. 22. Remove front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All vehicles: Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 1. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 3. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 4. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 5. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 6. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 7. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7842 8. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 9. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 10. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector. Install the driver air bag connector access cover. 11. Remove the special tool from the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector. Close the glove compartment. 12. Connect the battery ground cable. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 13.. Prove out the air bag system. For additional information, refer to section 501-20B: Occupant Restraints - Passive - Supplemental Air Bag System Diagnosis and Testing. 14. Check the restraint system for correct operation. Rear Door Non-Functional - Latch Replacement REMOVAL 1. Remove rear-seat lower cushion(s). All vehicles: 2. Remove door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Position aside water shield. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 4. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems Rear Door Latch Removal and Installation". INSTALLATION 1. Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install rear-seat lower cushion(s). All Doors Non-Functional - Latch Replacement REMOVAL 1. Open tailgate to access rear doors. NOTE REAR DOORS MUST BE OPENED BEFORE FRONT DOORS CAN BE OPENED. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7843 2. Remove rear-seat lower cushion(s). All vehicles: 3. Remove rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 4. Position watershield aside. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 5. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems " Rear Door Latch 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 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 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. NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR 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. NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. ALL VEHICLES 6. Move the front seat(s) to center position and the affected door glass into the completely down. 7. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 8. Lower the glove compartment by depressing the locking tabs and disconnect the passenger air bag module electrical connector. Connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 9. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7844 10. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 11. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety belt pretensioner body harness electrical connector. 12. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 13. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 14. Connect the battery ground cable. 15. Remove the front seat rear seat-track to floor nuts. 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. 16. Remove the front seat rear seat-track to floor bolts and remove the seat through rear doors. 17. Remove the safety belt D-ring cover(s) and bolt(s). 18. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 19. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers ^ Remove the front door scuff plate trim panel(s) 20. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 21. Remove the screw from front door latch release handle bezel and remove bezel. 22. Remove door handle cup screw. CAUTION DO NOT SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 23. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. 24. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating fever and pry up (Figure 2, passenger front door shown, all doors similar). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7845 CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 25. Open door(s), and move glass to the up position. 26. Remove last screw and remove and the door trim panel(s). 27. Remove door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All Vehicles: 1. Install new rear door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 4. Install rear-seat lower cushion(s). 5. Install new front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 6. Install front door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 7. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 8. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 9. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 10. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 11. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. 12. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 13. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 14. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector, and install the driver air bag connector access cover. 15. Remove the special tool to the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector, and close the glove compartment. 16. Connect the battery ground cable. For additional information, refer to section 414-01: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7846 Battery, Mounting and Cables General Procedures "Battery Disconnect". 17. Prove out the air bag system. For additional information, refer to section 501-2DB: Occupant Restraints Passive - Supplemental Air Bag System Diagnosis and Testing. 18. Check the restraint system for correct operation. 19. Close tailgate. Technical Service Bulletin # 02-9-3 Date: 020513 Doors - Unable to Open Article No. 02-9-3 05/13/02 BODY - UNABLE TO OPEN DOORS FORD: 2001-2002 ESCAPE ISSUE Some vehicles built before 12/15/01 may exhibit door latches that will not open. The outside handle and inside handle can be moved freely but latch remains locked. This may occur if the locked door's outside handle is lifted at the same time as the power lock button on either the key fob or the door panel is pressed. ACTION Refer to the follow Service Procedure to open door(s) and replace door latch per Workshop Manual Section 501-14: Handles, Locks, Latches and Entry Systems. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020903A Follow Service Procedure 1.5 Hrs. To Open Door And Replace Door Latch: One Front Door 020903B Follow Service Procedure 2.3 Hrs. To Open Doors And Replace Door Latches: Both Front Doors 020903C Follow Service Procedure 1.8 Hrs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7847 To Open Doors And Replace Door Latches: One Front Door One Rear Door 020903D Follow Service Procedure 2.8 Hrs. To Open Doors And Replace Door Latches: Both Front Doors One Rear Door 020903E Follow Service Procedure 2.2 Hrs. To Open Doors And Replace Door Latches: One Front Door Both Rear Doors 020903F Follow Service Procedure 0.6 Hr. To Open Door And Replace Door Latch: One Rear Door 020903G Follow Service Procedure 0.9 Hr. To Open Doors And Replace Door Latches: Both Rear Doors 020903H Follow Service Procedure 3.1 Hrs. To Open Doors And Replace Door Latches: Both Front And Both Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 5421813 41 OASIS CODES: 112000 Information Front Door Non-Functional - Latch Replacement Use the procedure below titled "Front Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. Rear Door Non-Functional - Latch Replacement Use the procedure below titled "Rear Door Non-Functional Latch Replacement" to gain access and replace the failed door latch mechanism. All Doors Non-Functional - Latch Replacement Use the procedure below titled "All Doors Non-Functional - Latch Replacement" to gain access and replace the failed door latch mechanism. Front Door Non-Functional - Latch Replacement 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7848 NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR 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. ALL VEHICLES NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. 1. Move the front seat(s) to center position and the affected door glass completely down. 2. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 3. Lower the glove compartment by depressing the locking tabs, and disconnect the passenger air bag module electrical connector and connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 4. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: 5. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 6. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety' belt pretensioner body harness electrical connector. 7. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 8. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 9. Connect the battery ground cable. 10. Remove the front seat rear seat-track to floor nuts. 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. 11. Remove the front seat, front seat-track to floor bolts and remove the seat. 12. Remove the safety belt D-ring cover(s) and bolt(s). 13. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 14. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7849 ^ Remove the front door scuff plate trim panel(s) 15. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 16. Remove the screw from front door latch release handle bezel and remove bezel. 17. Remove door handle cup screw. CAUTION DO NOT TO SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 18. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7850 19. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating lever and pry up (Figure 2, passenger front door shown, all doors similar). CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 20. Open door, and move glass to the up position. 21. Remove last screw and remove and the door trim panel. 22. Remove front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All vehicles: Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 1. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 3. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 4. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 5. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 6. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 7. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7851 8. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 9. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 10. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector. Install the driver air bag connector access cover. 11. Remove the special tool from the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector. Close the glove compartment. 12. Connect the battery ground cable. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 13.. Prove out the air bag system. For additional information, refer to section 501-20B: Occupant Restraints - Passive - Supplemental Air Bag System Diagnosis and Testing. 14. Check the restraint system for correct operation. Rear Door Non-Functional - Latch Replacement REMOVAL 1. Remove rear-seat lower cushion(s). All vehicles: 2. Remove door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Position aside water shield. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 4. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems Rear Door Latch Removal and Installation". INSTALLATION 1. Install new latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install rear-seat lower cushion(s). All Doors Non-Functional - Latch Replacement REMOVAL 1. Open tailgate to access rear doors. NOTE REAR DOORS MUST BE OPENED BEFORE FRONT DOORS CAN BE OPENED. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7852 2. Remove rear-seat lower cushion(s). All vehicles: 3. Remove rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 4. Position watershield aside. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. NOTE USING A SMALL SCREWDRIVER, INSERT SCREWDRIVER INTO LATCH ASSEMBLY AT OUTSIDE BASE OF ELECTRICAL CONNECTOR BELOW METAL ACTUATING LEVER AND PRY UP (FIGURE 2, PASSENGER FRONT DOOR SHOWN, ALL DOORS SIMILAR). 5. Remove latch. For additional information refer to section 501-14: Handles, Latches and Entry Systems " Rear Door Latch 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 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 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. NOTE 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 RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED UNDER THE SEATS IN THE SIDE AIR BAG TO FLOOR 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. NOTE VEHICLE NEEDS TO BE ACCESSED FROM AN ALTERNATE DOOR TO BEGIN PROCEDURE. ALL VEHICLES 6. Move the front seat(s) to center position and the affected door glass into the completely down. 7. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". 8. Lower the glove compartment by depressing the locking tabs and disconnect the passenger air bag module electrical connector. Connect the special tool (# 418-F468) to the instrument panel harness side of the passenger air bag module electrical connector. 9. Lower the driver air bag connector access cover on steering wheel and disconnect the driver air bag module electrical connector. Connect the special tool (# 418-F468) to the steering column harness side of the driver air bag module electrical connector. Vehicles equipped with side air bags: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7853 10. Disconnect the passenger seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the passenger seat side air bag module body harness electrical connector. All vehicles: 11. Disconnect the passenger seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the passenger seat safety belt pretensioner body harness electrical connector. 12. Disconnect the driver seat safety belt pretensioner electrical connector located under seat and connect the special tool (# 418-F470) to the driver seat safety belt pretensioner body harness electrical connector. Vehicles equipped with side air bags: 13. Disconnect the driver seat side air bag module electrical connector located under seat and connect the special tool (# 418-F468) to the driver seat side air bag module body harness electrical connector. All vehicles: 14. Connect the battery ground cable. 15. Remove the front seat rear seat-track to floor nuts. 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. 16. Remove the front seat rear seat-track to floor bolts and remove the seat through rear doors. 17. Remove the safety belt D-ring cover(s) and bolt(s). 18. Position the front and rear door weatherstrips aside and remove the upper B-pillar trim panel(s). 19. Remove the front and rear door scuff plate trim panel(s). ^ Remove the pin-type retainers ^ Remove the front door scuff plate trim panel(s) 20. Remove lower B-pillar trim to gain access to screw that is horizontal in door panel and remove screw (Figure 1). NOTE ONE SCREW AT TOP FRONT CORNER OF DOOR PANEL, WHICH TOUCHES DASH, CANNOT BE REMOVED UNTIL DOOR IS OPEN. 21. Remove the screw from front door latch release handle bezel and remove bezel. 22. Remove door handle cup screw. CAUTION DO NOT SCRATCH DOOR WHEN POSITIONING ASIDE DOOR PANEL. CAUTION MOVING DOOR PANEL ASIDE MORE THAN 6 INCHES WILL CAUSE DOOR PANEL TO CREASE OR BREAK. 23. To gain access to latch area, peel back water shield and position aside. NOTE TO PREVENT DAMAGING DOOR WHEN ACCESSING LATCH, PROTECT WITH FENDER COVER. NOTE IF LEVER WILL NOT MOVE FREELY, CYCLE THE DOOR LOCK BUTTON AND HANDLE TO FREE LEVER. 24. From outside vehicle, reach in with a small screwdriver, insert screwdriver into latch assembly at outside base of electrical connector below metal actuating fever and pry up (Figure 2, passenger front door shown, all doors similar). Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7854 CAUTION WHEN OPENING DOOR BE CAREFUL NOT TO DAMAGE DOOR PANEL. 25. Open door(s), and move glass to the up position. 26. Remove last screw and remove and the door trim panel(s). 27. Remove door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems Removal and Installation. INSTALLATION All Vehicles: 1. Install new rear door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Rear Door Latch Removal and Installation." 2. Install rear door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Rear Door Trim Panel Removal and Installation." 3. Install B-pillar trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "B-pillar Trim Panel Removal and Installation." 4. Install rear-seat lower cushion(s). 5. Install new front door latch. For additional information refer to section 501-14: Handles, Locks, Latches and Entry Systems "Front Door Latch Removal and Installation." 6. Install front door trim panel. For additional information refer to section 501-05: Interior Trim and Ornamentation "Front Door Trim Panel Removal and Installation." 7. Install the seat(s) and install the seat track to floor bolts and torque to 48 N.m (35 Lb-ft). 8. Install the rear seat track to floor nuts and torque to 48 N.m (35 Lb-ft). 9. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to section 414-01: Battery, Mounting and Cables General Procedures "Battery Disconnect". Vehicles equipped with side air bags: 10. Remove the special tool from the passenger seat side air bag module body harness electrical connector and connect the passenger seat side air bag module electrical connector. All vehicles: 11. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector and connect the passenger seat safety belt pretensioner electrical connector. 12. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector and connect the driver seat safety belt pretensioner electrical connector. Vehicles equipped with air bags: 13. Remove the special tool from the driver seat side air bag module body harness electrical connector and connect the driver seat side air bag module electrical connector. All vehicles: 14. Remove the special tool from the steering column harness side of the driver air bag module electrical connector and connect the driver air bag module electrical connector, and install the driver air bag connector access cover. 15. Remove the special tool to the instrument panel harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector, and close the glove compartment. 16. Connect the battery ground cable. For additional information, refer to section 414-01: Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 7855 Battery, Mounting and Cables General Procedures "Battery Disconnect". 17. Prove out the air bag system. For additional information, refer to section 501-2DB: Occupant Restraints Passive - Supplemental Air Bag System Diagnosis and Testing. 18. Check the restraint system for correct operation. 19. Close tailgate. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Page 7856 Rear Door Latch: Service and Repair 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. 5. Disconnect the exterior door handle actuating rod. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Page 7857 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 REMOVAL Vehicles with manual windows 1. Remove the rear door manual window regulator handle. 1 Release the clip. 2 Remove the rear door manual window regulator handle. All vehicles 2. Remove the rear door latch release handle bezel. 1 Remove the screw. 2 Remove the rear door latch release handle bezel. 3. Remove the door handle cup screw. 4. Remove the rear door sail panel. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 7861 5. Remove the rear door trim panel. ^ Disconnect the electrical connector. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments Rear Door Striker: Adjustments 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. Check the adjustment. Repeat the procedure as necessary. NOTE: The rear door is shown, the front door is similar. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 7871 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 7872 2 Remove the nuts. INSTALLATION All vehicles 1. To install, reverse the removal procedure. ^ Cycle the door glass to make sure of correct window glass engagement. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service Precautions > Page 7877 Hood Latch: Service and Repair REMOVAL 1. Remove the hood latch nut. 2. Remove the hood latch bolts. NOTE: Mark the hood latch position prior to removal of the bolts. 3. Remove the hood latch. 1 Release the cable conduit. 2 Disconnect the cable. 3 Remove the hood latch. INSTALLATION Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service Precautions > Page 7878 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. 6. Tighten the hood latch bolts and nut. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service Precautions > Page 7879 7. Verify the hood latch striker is fully engaging the hood latch. ^ Repeat previous steps as necessary. CAUTION: Make sure the hood latch is fully engaged. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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. Remove the hood latch release handle. NOTE: The hood latch release handle cable must be pulled through the dash panel into the passenger compartment. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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. Disconnect the two liftgate window glass cylinders. 1 Slide the spring retainer to the end of the socket. 2 Disconnect the socket from the ball stud. NOTE: An assistant may be needed to carry out this step. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 7891 6. Remove the two liftgate window glass hinge nuts. NOTE: An assistant may be needed to carry out this step. INSTALLATION 1. To install, reverse the removal procedure. ^ Transfer components as necessary. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 7898 Power Trunk / Liftgate Lock Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 7899 Liftgate Door Lock Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7908 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7909 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7910 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7911 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7912 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7913 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7914 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7915 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7916 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7926 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7927 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7928 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7929 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7930 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7931 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7932 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7933 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7934 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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. To install, reverse the removal procedure. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 7941 Trunk / Liftgate Latch: Service and Repair 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. 1 Remove the screw. 2 Remove the nuts. INSTALLATION 1. To install, reverse the removal procedure. ^ Transfer all necessary components. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 7942 Trunk / Liftgate Latch: Service and Repair 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. Remove the liftgate window latch. 1 Remove the bolts. 2 Remove the latch. NOTE: Mark the position of the liftgate window latch prior to removing the nuts. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 7943 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. 3. Install the liftgate trim panel. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 arms. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7966 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7967 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7973 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7974 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 7975 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 7976 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 7977 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 7978 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 7979 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 7980 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 7981 Front Subframe: Service and Repair SUBFRAME - FRONT Special Tool(S) Special Tool(s) Removal and Installation 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 7982 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 bolts. 2 Remove the crossmember. 9. Remove the front transmission mount bolt. 10. Remove the engine support crossmember bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 7983 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 7984 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7993 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 7994 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8000 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8001 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8002 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8003 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8004 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8005 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8006 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8007 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8016 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8017 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8023 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8024 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 8025 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 8026 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 8027 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 8028 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 8029 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 8030 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 8031 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 8032 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 8033 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8042 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8043 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8049 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8050 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8051 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8052 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8053 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8054 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8055 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8056 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair RADIATOR GRILLE Removal and Installation 1. Remove the front bumper cover. 2. Release the nine clips and remove the radiator grille. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications Console: Specifications Hood Latch Release Handle Bolts 6 Nm 53 Lb-In Floor Console Bolts 6 Nm 53 Lb-In Floor Console Bracket Bolts 6 Nm 53 Lb-In Steering Column Coupler Nut 23 Nm 17 Lb-Ft Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications > Page 8064 Console: Description and Operation Console - Overhead The overhead console may consists 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console - High Series > Page 8067 Console: Service and Repair Floor Console - Low Series REMOVAL 1. Remove the floor console front finish panel. 1 If equipped, 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console - High Series > Page 8068 4. Remove the floor console. 1 Remove the rear two bolts. 2 Remove the floor console. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8075 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8076 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8077 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8078 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8079 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8080 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8089 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8090 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8091 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8092 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8093 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8099 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8100 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8101 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8102 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8103 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 8104 Headliner: Service and Repair 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. 3. Remove the eight passenger assist handle covers. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 8105 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 8106 9. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 8107 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 8108 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 REMOVAL 1. 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. 5. Remove the front door scuff plate trim panel. 1 Remove the pin-type retainers. 2 Remove the front door scuff plate trim panel. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 8113 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 8114 Trim Panel: Service and Repair 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 8115 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. Disconnect the accessory socket connector. (Left side) 9. Remove the C-pillar trim panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 8116 Trim Panel: Service and Repair Rear Door Trim Panel REMOVAL Vehicles with manual windows 1. Remove the rear door manual window regulator handle. 1 Release the clip. 2 Remove the rear door manual window regulator handle. All vehicles 2. Remove the rear door latch release handle bezel. 1 Remove the screw. 2 Remove the rear door latch release handle bezel. 3. Remove the door handle cup screw. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 8117 4. Remove the rear door sail panel. 5. Remove the rear door trim panel. ^ Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair REMOVAL NOTE: ^ When a new lock cylinder is installed, the door lock cylinder, liftgate lock cylinder and ignition lock cylinder should be installed as a set. This will eliminate carrying an extra key which will fit only one lock. If a new key is to be used, the new key code number is stamped on a metal tag attached to the key. ^ 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. Remove the exterior front door handle. NOTE: Make sure the window glass is in the raised position. 2. Remove and discard the door latch screws. 3. Remove the door lock cylinder. 1 Release the clips. 2 Remove the lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 8128 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 8129 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Unit Power Door Lock Actuator: Diagrams Door Lock Unit Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Unit > Page 8138 Power Door Lock Actuator: Diagrams Door Lock Actuator Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch > Page 8146 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side Power Door Lock Switch: Testing and Inspection Driver Side Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 8149 Door Lock Switch, Driver Side Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 8150 Power Door Lock Switch: Testing and Inspection Passenger Side Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 8151 Door Lock Switch, Passenger Side Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 8156 Power Mirror Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 8157 Exterior Rear View Mirror Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 8158 Exterior Rear View Mirror Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 8164 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 8165 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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. Exterior paint color codes may be listed as a two-part code. The first set of paint code characters indicate the primary body color. The second set of paint code characters (if applicable), indicate a two-tone body color or accent body color. Primary Color Codes - BZ - Chrome Yellow - E4 - Vermijion - UA - Ebony - PX - Dark Highland Green - YZ - Oxford White - CX - Dark Shadow Gray - TL - Satin Silver L2 - True Blue Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 8168 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations View 151-21 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 8179 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 8180 Sunroof / Moonroof Module: Service and Repair REMOVAL 1. Remove the headliner. 2. Remove the roof 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair Luggage Rack: Service and Repair ROOF RACK Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Page 8185 Part 2 Removal and Installation 1. NOTE: Individual components can be removed without following the entire sequence shown. LH and RH stopblocks are not interchangeable. Have an assistant help with sliding the inner roof rack assembly from the upper slide rails. Remove in the order indicated in the table. 2. Install in the reverse order of removal. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams > Page 8190 Sunroof / Moonroof Motor: Service and Repair 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. Connect the roof opening panel motor electrical connector. NOTE: The roof opening panel should be in the closed position. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Roof Opening Panel Position Switch > Page 8195 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8203 Sunroof / Moonroof Drain: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations View 151-21 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 8210 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 8211 Sunroof / Moonroof Module: Service and Repair REMOVAL 1. Remove the headliner. 2. Remove the roof 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 8219 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. ^ 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 AFTERWARD. ^ 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 8220 Power Seat Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 8221 Seat Adjust Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 8222 Power Seat Switch: Service and Repair 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 AFTERWARD. ^ 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. 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 air bag system is being repaired the air bag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 8223 2. Remove the seat control switch knob. 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. 4. Remove the seat control switch. 1 Remove the screws. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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. ^ 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 AFTERWARD. ^ 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions > Technician Safety Information > Page 8228 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion: Service and Repair Front With Side Air Bag 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. ^ 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 AFTERWARD. ^ 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. 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 air bag system is being repaired the air bag system must be deactivated per the deactivation procedure Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8231 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. ^ Manual seat shown, power seat similar. 1. Position the front seats forward. 2. Disconnect the battery ground cable and wait at least one minute. 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. 5. Disconnect the driver seat safety belt pretensioner electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8232 6. Connect the special tool to the driver seat safety belt pretensioner body harness electrical connector. 7. Disconnect the passenger seat safety belt pretensioner electrical connector. 8. Connect the special tool to the passenger seat safety belt pretensioner body harness electrical connector. 9. Disconnect the passenger seat side air bag module electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8233 10. Connect the special tool to the passenger seat side air bag module body harness electrical connector. 11. Lower the glove compartment. ^ Depress 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8234 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. Remove the driver seat. ^ If equipped with power seats, disconnect the electrical connector. 1 Remove the seat track to floor bolts. 2 Remove the driver seat. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8235 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. 23. Disconnect the seat cushion trim cover J-clips. 24. Remove the front seat cushion trim and pad from the front seat cushion frame. 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 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 AFTERWARD. ^ 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. 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8236 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 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. 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. 3. Connect the seat cushion trim cover J-clips. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8237 4. Install the driver seat. 1 Position the driver seat. 2 Install the seat track to floor bolts. ^ If equipped with power seats, connect the electrical connector. 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. 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. 9. Remove the special tool from the driver seat side air bag module body harness 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8238 10. Connect the driver seat side air bag module electrical connector. 11. Remove the special tool from the driver side safety belt pretensioner body harness 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. Connect the driver seat 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. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8239 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 seat safety belt pretensioner electrical connector. 18. Remove the special tool from the passenger seat side air bag module body harness 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 seat side air bag module electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8240 20. Remove the special tool to the instrument panel 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. 21. Connect the passenger air bag module electrical connector. 22. Raise the glove compartment. ^ Depress the locking tabs. 23. Remove the special tool from the steering column harness side of the driver 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. 24. Connect the driver air bag module electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8241 25. Install the driver air bag connector access cover. 26. Connect the battery ground cable. 27. Prove out the air bag system. 28. Check the restraint system for correct operation. Without Side Air Bag 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. ^ 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 AFTERWARD. ^ 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, Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8242 SEATS AND HOOD LATCHES. REFER TO THE APPROPRIATE WORKSHOP MANUAL 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 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. ^ Manual seat shown, power seat similar. 1. Position the front seats forward. 2. Disconnect the battery ground cable and wait at least one minute. 3. Disconnect the driver seat safety belt pretensioner electrical connector. 4. Connect the special tool to the driver seat safety belt pretensioner body harness electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8243 5. Disconnect the passenger seat safety belt pretensioner electrical connector. 6. Connect the special tool to the passenger seat safety belt pretensioner body harness electrical connector. 7. Lower the glove compartment. ^ Depress the locking tabs. 8. Disconnect the passenger air bag module electrical connector. 9. Connect the special tool to the instrument panel harness side of the passenger air bag module electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8244 10. Lower the driver air bag connector access cover. 11. Disconnect the driver air bag module electrical connector. 12. Connect the special tool to the steering column harness side of the driver air bag module electrical connector. 13. Connect the battery ground cable. 14. Prove out the air bag system. 15. Remove the seat track to floor nuts. 16. Position the driver seat rearward. 17. If equipped with power seats, disconnect the negative battery cable. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8245 18. Remove the driver seat. ^ If equipped with power seats, disconnect the electrical connector. 1 Remove the seat track to floor bolts. 2 Remove the driver seat. 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. 19. Disconnect the seat cushion trim cover J-clips. 20. Remove the front seat cushion trim and pad from the front seat cushion frame. 21. 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. ^ 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 AFTERWARD. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8246 ^ 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. 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 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8247 3. Connect the seat cushion trim cover J-clips. 4. Install the driver seat. 1 Position the driver seat. 2 Install the seat track to floor bolts. ^ If equipped with power seats, connect the electrical connector. 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. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8248 9. Remove the special tool from the driver side safety belt pretensioner body harness 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. Connect the driver seat safety belt pretensioner electrical connector. 11. Connect the battery ground cable. 12. With the remaining special tools still in place, prove out the air bag system. 13. Disconnect the battery ground cable and wait at least one minute. 14. Remove the special tool from the passenger seat safety belt pretensioner body harness 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8249 15. Connect the passenger seat safety belt pretensioner electrical connector. 16. Remove the special tool to the instrument panel 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. 17. Connect the passenger air bag module electrical connector. 18. Raise the glove compartment. ^ Depress the locking tabs. 19. Remove the special tool from the steering column harness side of the driver 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8250 VEHICLE SAFETY STANDARDS. 20. Connect the driver air bag module electrical connector. 21. Install the driver air bag connector access cover. 22. Connect the battery ground cable. 23. Prove out the air bag system. 24. Check the restraint system for correct operation. With Side Air Bag 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. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8251 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 AFTERWARD. ^ 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. 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 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. 1. Position the front seats forward. 2. Disconnect the battery ground cable and wait at least one minute. 3. Disconnect the passenger seat side air bag module electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8252 4. Connect the special tool to the passenger seat side air bag module body harness electrical connector. 5. Disconnect the passenger seat safety belt pretensioner electrical connector. 6. Connect the special tool to the passenger seat safety belt pretensioner body harness electrical connector. 7. Disconnect the driver seat safety belt pretensioner electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8253 8. Connect the special tool to the driver side seat safety belt pretensioner body harness electrical connector. 9. Disconnect the driver seat side air bag module electrical connector. 10. Connect the special tool to the driver seat side air bag module body harness electrical connector. 11. Lower the driver air bag connector access cover. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8254 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. ^ Depress the locking tabs. 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8255 19. Remove the seat track to floor nuts. 20. Position the passenger seat rearward. 21. Remove the passenger seat. 1 Remove the seat track to floor bolts. 2 Remove the passenger seat. 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. 22. Disconnect the seat cushion trim cover J-clips. 23. Remove the front seat cushion trim and pad from the front seat cushion frame. 24. Separate the front seat cushion trim from the front seat cushion pad. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8256 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. ^ 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 AFTERWARD. ^ 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. 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8257 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. 3. Connect the seat cushion trim cover J-clips. 4. Install the passenger seat. 1 Position the passenger seat. 2 Install the seat track to floor bolts. 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. 5. Position the passenger seat forward. 6. Install the seat track to floor nuts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8258 7. Disconnect the battery ground cable and wait at least one minute. 8. Remove the special tool from the passenger seat side air bag module body harness 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 seat air bag module electrical connector. 10. Remove the special tool from the passenger seat safety belt pretensioner body harness 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8259 11. Connect the passenger seat 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. Remove the special tool from the driver seat safety belt pretensioner body harness 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. 16. Connect the driver seat safety belt pretensioner electrical connector. 17. Remove the special tool from the driver seat side air bag module body harness electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8260 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 seat side air bag module electrical connector. 19. Remove the special tool from the steering column harness side of the driver 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. 20. Connect the driver air bag module electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8261 21. Install the driver air bag connector access cover. 22. Remove the special tool to the instrument panel 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. 23. Connect the passenger air bag module electrical connector. 24. Raise the glove compartment. ^ Depress the locking tabs. 25. Connect the battery ground cable. 26. Prove out the air bag system. 27. Check the restraint system for correct operation. Without Side Air Bag Special Tool(s) SPECIAL TOOL(S) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8262 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. ^ 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 AFTERWARD. ^ 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. 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 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. 1. Position the front seats forward. 2. Disconnect the battery ground cable and wait at least one minute. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8263 3. Disconnect the passenger seat safety belt pretensioner electrical connector. 4. Connect the special tool to the passenger seat safety belt pretensioner body harness electrical connector. 5. Disconnect the driver seat safety belt pretensioner electrical connector. 6. Connect the special tool to the driver side seat safety belt pretensioner body harness electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8264 7. Lower the driver air bag connector access cover. 8. Disconnect the driver air bag module electrical connector. 9. Connect the special tool to the steering column harness side of the driver air bag module electrical connector. 10. Lower the glove compartment. ^ Depress the locking tabs. 11. Disconnect the passenger air bag module electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8265 12. Connect the special tool to the instrument panel harness side of the passenger air bag module electrical connector. 13. Connect the battery ground cable. 14. Prove out the air bag system. 15. Remove the seat track to floor nuts. 16. Position the passenger seat rearward. 17. Remove the passenger seat. 1 Remove the seat track to floor bolts. 2 Remove the passenger seat. 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. 18. Disconnect the seat cushion trim cover J-clips. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8266 19. Remove the front seat cushion trim and pad from the front seat cushion frame. 20. 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. ^ 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 AFTERWARD. ^ 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. 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 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8267 ^ 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. 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. 3. Connect the seat cushion trim cover J-clips. 4. Install the passenger seat. 1 Position the passenger seat. 2 Install the seat track to floor bolts. 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. 5. Position the passenger seat forward. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8268 6. Install the seat track to floor nuts. 7. Disconnect the battery ground cable and wait at least one minute. 8. Remove the special tool from the passenger seat safety belt pretensioner body harness 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 seat safety belt pretensioner electrical connector. 10. Connect the battery ground cable. 11. With the remaining special tools still in place, prove out the air bag system. 12. Disconnect the battery ground cable and wait at least one minute. 13. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8269 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. 14. Connect the driver seat safety belt pretensioner electrical connector. 15. Remove the special tool from the steering column harness side of the driver 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. 16. Connect the driver air bag module electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8270 17. Install the driver air bag connector access cover. 18. Remove the special tool to the instrument panel 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. 19. Connect the passenger air bag module electrical connector. 20. Raise the glove compartment. ^ Depress the locking tabs. 21. Connect the battery ground cable. 22. Prove out the air bag system. 23. Check the restraint system for correct operation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8271 Seat Cushion: Service and Repair Rear 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. 5. Remove the rear seat cushion trim from the rear seat cushion pad. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front > Page 8272 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair Seat Latch: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 AFTERWARD. ^ 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service Precautions > Technician Safety Information > Page 8280 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat Track: Service and Repair Driver 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. ^ 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 AFTERWARD. ^ 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8283 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. ^ Manual seat track shown, power seat track similar. 1. Position the front seats forward. 2. Disconnect the battery ground cable and wait at least one minute. 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. 5. Disconnect the driver seat safety belt pretensioner electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8284 6. Connect the special tool to the driver seat safety belt pretensioner body harness electrical connector. 7. Disconnect the passenger seat safety belt pretensioner electrical connector. 8. Connect the special tool to the passenger seat safety belt pretensioner body harness electrical connector. 9. Disconnect the passenger seat side air bag module electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8285 10. Connect the special tool to the passenger seat side air bag module body harness electrical connector. 11. Lower the glove compartment. ^ Depress 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8286 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. Remove the driver seat. ^ If equipped with power seats, disconnect the electrical connector. 1 Remove the seat track to floor bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8287 2 Remove the driver seat. 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. 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 seat, disconnect the electrical connector. 25. Remove the inboard seat cushion side shield. 26. Remove the front seat backrest bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8288 27. Remove the front seat backrest. 1 Remove the pivot nut. 2 Remove the backrest. NOTE: If equipped with a side air bag module, note the routing of the wiring harness for installation. 28. Remove the front seat cushion pan. 1 Remove the bolts. 2 Remove the front seat cushion pan. 29. If equipped with manual seats, remove the seat adjuster. ^ Unclip the seat adjuster pins. 30. Remove the safety belt pretensioner from the seat track. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8289 1 Remove the bolt. 2 Remove the safety belt pretensioner. NOTE: Note the routing of the wiring harness for installation. 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 GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. ^ 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. 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8290 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. 4. Install the front seat backrest. 1 Install the backrest. 2 Install the pivot nut. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8291 5. Install the front seat backrest bolts. 6. Install the inboard seat cushion side shield. 7. Install the outboard seat cushion side shield. 1 Install the shield. ^ If equipped with a power seat, connect the electrical connector. 2 Install the screw. 3 Install the seat backrest handle. 8. If equipped, install the seat height adjustment control. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8292 9. Install the driver seat. 1 Position the driver seat. ^ If equipped with power seats, connect the electrical connector. 2 Install the seat track to floor bolts. 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. 10. If equipped with power seats, connect the battery ground cable. 11. Position the driver seat forward. 12. Install the seat track to floor nuts. 13. If equipped with power seats, disconnect the battery ground cable and wait one minute. 14. Remove the special tool from the driver seat side air bag module body harness 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8293 15. Connect the driver seat side air bag module electrical connector. 16. Remove the special tool from the driver seat side safety belt pretensioner body harness 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 driver seat safety belt pretensioner electrical connector. 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. Remove the special tool from the passenger seat safety belt pretensioner body harness electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8294 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 passenger seat safety belt pretensioner electrical connector. 23. Remove the special tool from the passenger seat side air bag module body harness 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. 24. Connect the passenger seat side air bag module electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8295 25. Remove the special tool to the instrument panel 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. 26. Connect the passenger air bag module electrical connector. 27. Raise the glove compartment. ^ Depress the locking tabs. 28. Remove the special tool from the steering column harness side of the driver 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. 29. Connect the driver air bag module electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8296 30. Install the driver air bag connector access cover. 31. Connect the battery ground cable. 32. Prove out the air bag system. 33. Check the restraint system for correct operation. 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. ^ 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 AFTERWARD. ^ 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, Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8297 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). ^ 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 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. ^ Manual seat track shown, power seat track similar. 1. Position the front seats forward. 2. Disconnect the battery ground cable and wait at least one minute. 3. Disconnect the driver seat safety belt pretensioner electrical connector. 4. Connect the special tool to the driver seat safety belt pretensioner body harness electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8298 5. Disconnect the passenger seat safety belt pretensioner electrical connector. 6. Connect the special tool to the passenger seat safety belt pretensioner body harness electrical connector. 7. Lower the glove compartment. ^ Depress the locking tabs. 8. Disconnect the passenger air bag module electrical connector. 9. Connect the special tool to the instrument panel harness side of the passenger air bag module electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8299 10. Lower the driver air bag connector access cover. 11. Disconnect the driver air bag module electrical connector. 12. Connect the special tool to the steering column harness side of the driver air bag module electrical connector. 13. Connect the battery ground cable. 14. Prove out the air bag system. 15. Remove the seat track to floor nuts. 16. Position the driver seat rearward. 17. If equipped with power seats, disconnect the negative battery cable. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8300 18. Remove the driver seat. ^ If equipped with power seats, disconnect the electrical connector. 1 Remove the seat track to floor bolts. 2 Remove the driver seat. 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. 19. If equipped, remove the seat height adjustment control. 20. 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 seat, disconnect the electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8301 21. Remove the inboard seat cushion side shield. 22. Remove the front seat backrest bolts. 23. Remove the front seat backrest. 1 Remove the pivot nut. 2 Remove the backrest. NOTE: If equipped with a side air bag module, note the routing of the wiring harness for installation. 24. Remove the front seat cushion pan. 1 Remove the bolts. 2 Remove the front seat cushion pan. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8302 25. If equipped with manual seats, remove the seat adjuster. ^ Unclip the seat adjuster pins. 26. Remove the safety belt pretensioner from the seat track. 1 Remove the bolt. 2 Remove the safety belt pretensioner. NOTE: Note the routing of the wiring harness for installation. 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 GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. ^ 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. 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 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 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8303 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8304 4. Install the front seat backrest. 1 Install the backrest. 2 Install the pivot nut. 5. Install the front seat backrest bolts. 6. Install the inboard seat cushion side shield. 7. Install the outboard seat cushion side shield. 1 Install the shield. ^ If equipped with a power seat, connect the electrical connector. 2 Install the screw. 3 Install the seat backrest handle. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8305 8. If equipped, install the seat height adjustment control. 9. Install the driver seat. 1 Position the driver seat. ^ If equipped with power seats, connect the electrical connector. 2 Install the seat track to floor bolts. 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. 10. If equipped with power seats, connect the battery ground cable. 11. Position the driver seat forward. 12. Install the seat track to floor nuts. 13. If equipped with power seats, disconnect the battery ground cable and wait one minute. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8306 14. Remove the special tool from the driver seat side safety belt pretensioner body harness 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 seat safety belt pretensioner electrical connector. 16. Connect the battery ground cable. 17. With the remaining special tools still in place, prove out the air bag system. 18. Disconnect the battery ground cable and wait at least one minute. 19. Remove the special tool from the passenger seat safety belt pretensioner body harness 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8307 20. Connect the passenger seat safety belt pretensioner electrical connector. 21. Remove the special tool to the instrument panel 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. 22. Connect the passenger air bag module electrical connector. 23. Raise the glove compartment. ^ Depress the locking tabs. 24. Remove the special tool from the steering column harness side of the driver air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8308 VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 25. Connect the driver air bag module electrical connector. 26. Install the driver air bag connector access cover. 27. Connect the battery ground cable. 28. Prove out the air bag system. 29. Check the restraint system for correct operation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8309 Seat Track: Service and Repair Passenger 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. ^ 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 AFTERWARD. ^ 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8310 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 1. Position the front seats forward. 2. Disconnect the battery ground cable and wait at least one minute. 3. Disconnect the passenger seat side air bag module electrical connector. 4. Connect the special tool to the passenger seat side air bag module body harness electrical connector. 5. Disconnect the passenger seat safety belt pretensioner electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8311 6. Connect the special tool to the passenger seat safety belt pretensioner body harness electrical connector. 7. Disconnect the driver seat safety belt pretensioner electrical connector. 8. Connect the special tool to the driver seat safety belt pretensioner body harness electrical connector. 9. Disconnect the driver seat side air bag module electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8312 10. Connect the special tool to the driver seat side air bag module body harness electrical connector. 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. ^ Depress the locking tabs. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8313 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. Remove the passenger seat. 1 Remove the seat track to floor bolts. 2 Remove the passenger seat. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8314 22. Remove the outboard seat cushion side shield. 1 Remove the seat backrest handle. 2 Remove the screw. 3 Remove the shield. 23. Remove the inboard seat cushion side shield. 24. Remove the front seat backrest bolts. 25. Remove the front seat backrest. 1 Remove the pivot nut. 2 Remove the backrest. NOTE: If equipped with a side air bag module, note the routing of the wiring harness for installation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8315 26. If equipped, remove the under seat storage bin. 27. Remove the front seat cushion pan. 1 Remove the bolts. 2 Remove the front seat cushion pan. 28. Remove the seat adjuster. ^ Unclip the seat adjuster pins. 29. Remove the safety belt pretensioner. 1 Remove the bolt. 2 Remove the safety belt pretensioner. NOTE: Note the routing of the wiring harness for installation. 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 GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8316 AFTERWARD. ^ 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. 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 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. 1. Install the safety belt pretensioner. 1 Install the safety belt pretensioner. 2 Install the bolt. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8317 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. If equipped, install the under seat storage bin. 5. Install the front seat backrest. 1 Install the backrest. 2 Install the pivot nut. 6. Install the front seat backrest bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8318 7. Install the inboard seat cushion side shield. 8. Install the outboard seat cushion side shield. 1 Install the shield. 2 Install the screw. 3 Install the seat backrest handle. 9. Install the passenger seat. 1 Position the passenger seat. 2 Install the seat track to floor bolts. 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. 10. Position the passenger seat forward. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8319 11. Install the seat track to floor nuts. 12. Remove the special tool from the passenger seat side air bag module body harness 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 seat side air bag module electrical connector. 14. Remove the special tool from the passenger seat safety belt pretensioner body harness 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8320 15. Connect the passenger seat safety belt pretensioner electrical connector. 16. Connect the battery ground cable. 17. With the remaining special tools still in place, prove out the air bag system. 18. Disconnect the battery ground cable and wait at least one minute. 19. Remove the special tool from the driver seat safety belt pretensioner body harness 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. 20. Connect the driver seat safety belt pretensioner electrical connector. 21. Remove the special tool from the driver seat side air bag module body harness electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8321 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 seat side air bag module electrical connector. 23. Remove the special tool from the steering column harness side of the driver 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. 24. Connect the driver air bag module electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8322 25. Install the driver air bag connector access cover. 26. Remove the special tool to the instrument panel 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. 27. Connect the passenger air bag module electrical connector. 28. Raise the glove compartment. ^ Depress the locking tabs. 29. Connect the battery ground cable. 30. Prove out the air bag system. 31. Check the restraint system for correct operation. Without Side Air Bag Special Tool(s) SPECIAL TOOL(S) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8323 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 AFTERWARD. ^ 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. 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 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 1. Position the front seats forward. 2. Disconnect the battery ground cable and wait at least one minute. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8324 3. Disconnect the passenger seat safety belt pretensioner electrical connector. 4. Connect the special tool to the passenger seat safety belt pretensioner body harness electrical connector. 5. Disconnect the driver seat safety belt pretensioner electrical connector. 6. Connect the special tool to the driver seat safety belt pretensioner body harness electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8325 7. Lower the driver air bag connector access cover. 8. Disconnect the driver air bag module electrical connector. 9. Connect the special tool to the steering column harness side of the driver air bag module electrical connector. 10. Lower the glove compartment. ^ Depress the locking tabs. 11. Disconnect the passenger air bag module electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8326 12. Connect the special tool to the instrument panel harness side of the passenger air bag module electrical connector. 13. Connect the battery ground cable. 14. Prove out the air bag system. 15. Remove the seat track to floor nuts. 16. Position the passenger seat rearward. 17. Remove the passenger seat. 1 Remove the seat track to floor bolts. 2 Remove the passenger seat. 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. 18. Remove the outboard seat cushion side shield. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8327 1 Remove the seat backrest handle. 2 Remove the screw. 3 Remove the shield. 19. Remove the inboard seat cushion side shield. 20. Remove the front seat backrest bolts. 21. Remove the front seat backrest. 1 Remove the pivot nut. 2 Remove the backrest. NOTE: If equipped with a side air bag module, note the routing of the wiring harness for installation. 22. If equipped, remove the under seat storage bin. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8328 23. Remove the front seat cushion pan. 1 Remove the bolts. 2 Remove the front seat cushion pan. 24. Remove the seat adjuster. ^ Unclip the seat adjuster pins. 25. Remove the safety belt pretensioner. 1 Remove the bolt. 2 Remove the safety belt pretensioner. NOTE: Note the routing of the wiring harness for installation. 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 GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8329 ^ 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. 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 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. 1. Install the safety belt pretensioner. 1 Install the safety belt pretensioner. 2 Install the bolt. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8330 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. If equipped, install the under seat storage bin. 5. Install the front seat backrest. 1 Install the backrest. 2 Install the pivot nut. 6. Install the front seat backrest bolts. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8331 7. Install the inboard seat cushion side shield. 8. Install the outboard seat cushion side shield. 1 Install the shield. 2 Install the screw. 3 Install the seat backrest handle. 9. Install the passenger seat. 1 Position the passenger seat. 2 Install the seat track to floor bolts. 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. 10. Position the passenger seat forward. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8332 11. Install the seat track to floor nuts. 12. Remove the special tool from the passenger seat safety belt pretensioner body harness 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 seat safety belt pretensioner electrical connector. 14. Connect the battery ground cable. 15. With the remaining special tools still in place, prove out the air bag system. 16. Disconnect the battery ground cable and wait at least one minute. 17. Remove the special tool from the driver seat safety belt pretensioner body harness electrical connector. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8333 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 seat safety belt pretensioner electrical connector. 19. Remove the special tool from the steering column harness side of the driver 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. 20. Connect the driver air bag module electrical connector. 21. Install the driver air bag connector access cover. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver > Page 8334 22. Remove the special tool to the instrument panel 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. 23. Connect the passenger air bag module electrical connector. 24. Raise the glove compartment. ^ Depress the locking tabs. 25. Connect the battery ground cable. 26. Prove out the air bag system. 27. Check the restraint system for correct operation. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 8335 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8345 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side Power Door Lock Switch: Testing and Inspection Driver Side Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 8348 Door Lock Switch, Driver Side Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 8349 Power Door Lock Switch: Testing and Inspection Passenger Side Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 8350 Door Lock Switch, Passenger Side Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 8354 Power Mirror Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 8355 Exterior Rear View Mirror Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 8356 Exterior Rear View Mirror Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 8360 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. ^ 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 AFTERWARD. ^ 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 8361 Power Seat Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 8362 Seat Adjust Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 8363 Power Seat Switch: Service and Repair 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 AFTERWARD. ^ 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. 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 air bag system is being repaired the air bag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 8364 2. Remove the seat control switch knob. 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. 4. Remove the seat control switch. 1 Remove the screws. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 8368 Power Trunk / Liftgate Lock Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 8369 Liftgate Door Lock Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Roof Opening Panel Position Switch > Page 8374 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 arms. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 05-22-11 > Nov > 05 > Body - Door Seal Squeaking Weatherstrip: Customer Interest Body - Door Seal Squeaking TSB 05-22-11 11/14/05 DOOR SEAL SQUEAKS FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some 2001-2005 Escape, 2005 Escape Hybrid and Mariners may exhibit squeaks from the shedlip seal for the doors. This seal runs along the top edge of the doors, above the top section of the individual door inner seals. This is most likely to be noticed at slow speeds and when the body is put into a twist. ACTION Replace the seals. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052211A 2001-2005 Escape, 2005 0.2 Hr. Escape Hybrid, 2005 Mariner: Replace The Shedlip Seal For Both Doors DEALER CODING CONDITION BASIC PART NO. CODE 7851222 41 OASIS CODES: 110000, 702000 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 05-22-11 > Nov > 05 > Body - Door Seal Squeaking Weatherstrip: All Technical Service Bulletins Body - Door Seal Squeaking TSB 05-22-11 11/14/05 DOOR SEAL SQUEAKS FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some 2001-2005 Escape, 2005 Escape Hybrid and Mariners may exhibit squeaks from the shedlip seal for the doors. This seal runs along the top edge of the doors, above the top section of the individual door inner seals. This is most likely to be noticed at slow speeds and when the body is put into a twist. ACTION Replace the seals. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052211A 2001-2005 Escape, 2005 0.2 Hr. Escape Hybrid, 2005 Mariner: Replace The Shedlip Seal For Both Doors DEALER CODING CONDITION BASIC PART NO. CODE 7851222 41 OASIS CODES: 110000, 702000 Disclaimer Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 8401 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 8402 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 8403 Brake Switch (Cruise Control): Description and Operation Brake Pressure Applied Brake Deactivator Switch The Brake Pressure Applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, witch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 8404 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams > Page 8408 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams > Page 8409 5. Remove the bolts and separate the speed control actuator from the bracket. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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. 1 Disconnect the cable from the throttle control linkage. 2 Squeeze the tabs and disconnect the speed control cable from the 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service Precautions > Page 8416 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service Precautions > Page 8417 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 8423 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 8424 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 8425 Brake Switch (Cruise Control): Description and Operation Brake Pressure Applied Brake Deactivator Switch The Brake Pressure Applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, witch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 8426 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service Precautions > Page 8430 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service Precautions > Page 8431 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8437 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8438 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8439 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8440 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8441 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8442 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8443 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8444 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8445 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8446 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8447 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8448 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8449 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8450 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8451 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8452 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8453 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8454 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8455 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8456 Cigarette Lighter: Electrical Diagrams Diagram 44-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8457 Diagram 44-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8464 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8465 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8466 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8467 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8468 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8469 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8482 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8483 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8484 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8485 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8486 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8487 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Selector Lever Indicator Bulb Instrument Panel Bulb: 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Selector Lever Indicator Bulb > Page 8492 Instrument Panel Bulb: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Selector Lever Indicator Bulb > Page 8493 Instrument Panel Bulb: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Relay > Component Information > Locations View 151-38 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Relay > Component Information > Locations > Page 8497 Accessory Relay (Audio, Instrument Cluster, GEM, & Mirrors) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Relay > Component Information > Locations > Page 8498 Instrument Panel Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Relay > Component Information > Locations > Page 8499 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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) Check Engine, Service Engine Soon Or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control Module (PCM) has detected an On Board Diagnostic (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 16). ^ 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. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Reading Diagnostic Trouble Codes/Performance Diagnostic Procedures/Quick Test ^ 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Page 8509 Oil Pressure Sender: Service and Repair Oil Pressure Sender Removal and Installation 1. Raise and support the vehicle. 2. Remove the right side splash shield. 3. NOTE: The A/C compressor has been removed for clarity. Remove the oil pressure sender. 1 Disconnect the electrical connector. 2 Remove the sender. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Diagrams > Page 8513 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Relay > Component Information > Locations View 151-38 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Relay > Component Information > Locations > Page 8518 Accessory Relay (Audio, Instrument Cluster, GEM, & Mirrors) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Relay > Component Information > Locations > Page 8519 Instrument Panel Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Relay > Component Information > Locations > Page 8520 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Page 8534 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Reversing Lamp <--> [Backup Lamp] > Backup Lamp Switch > Component Information > Locations View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Reversing Lamp <--> [Backup Lamp] > Backup Lamp Switch > Component Information > Diagrams > Transmission Range Sensor Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Reversing Lamp <--> [Backup Lamp] > Backup Lamp Switch > Component Information > Diagrams > Transmission Range Sensor > Page 8542 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8551 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 8557 (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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8560 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8561 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8562 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8563 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8564 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8565 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8566 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8567 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8568 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8569 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8570 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8571 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8572 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8573 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8574 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8575 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8576 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8577 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8578 Brake Lamp: Connector Views Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8579 Brake Lamp: Electrical Diagrams Diagram 90-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8580 Diagram 90-2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8583 Symptom Chart Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8584 Brake Lamp: Pinpoint Tests H1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8585 H2 - H3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8586 I1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8587 I2 J1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 8588 73III Automotive Meter Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Brake Pedal Position Switch Brake Pedal Position Switch: Description and Operation Brake Pedal Position Switch Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Brake Pedal Position Switch > Page 8594 Brake Pedal Position Switch: Description and Operation Brake Pressure Applied Brake Deactivator Switch Brake Pressure Applied Brake Deactivator Switch The Brake Pressure Applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, witch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Page 8595 Brake Pedal Position Switch: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams Cargo Lamp: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Page 8599 Cargo Lamp: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair Center Mounted Brake Lamp Bulb: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection Cornering Lamp: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Turn Signals; Testing and Inspection. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions Courtesy Lamp: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8611 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8612 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8613 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8614 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8615 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8616 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8617 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8618 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8619 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8620 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8621 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8622 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8623 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8624 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8625 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8626 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8627 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8628 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8629 Courtesy Lamp: Connector Views Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8630 Diagram 89-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Page 8631 Courtesy Lamp: Description and Operation 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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. 8. If the DTCs are retrieved that are not found in the following GEM Diagnostic Trouble Code (DTC) Index, refer to the master GEM Diagnostic Trouble Code (DTC) Index in Multifunction Electronic Control Module (General Module) at Accessories and Optional Equipment. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8634 Courtesy Lamp: Diagnostic Trouble Code Descriptions DTC Index B1317 - B1371 DTC Index B1571 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8635 Symptom Chart Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8636 Courtesy Lamp: Pinpoint Tests Test A: Interior Lamps Are Inoperative A1 - A3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8637 A3 - A4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8638 A5 - A6 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8639 A6 - A8 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8640 A8 Test B: Interior Lamps Stay On Continuously - Do Not Fade Out B1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8641 B2 - B3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8642 B4 - B5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8643 B6 - B7 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8644 B8 - B10 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8645 B11 - B12 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8646 B13 - B15 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8647 B16 - B17 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8648 B18 - B20 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8649 B21 - B22 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8650 B23 - B25 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8651 B26 - B27 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8652 B28 - B30 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8653 B31 - B32 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8654 B33 - B35 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8655 B35 - B36 Test C: Courtesy Lamp Do Not Turn ON With One Door Open Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8656 C1 - C2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8657 C2 - C4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8658 C4 D1 - D2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8659 D2 Test E: Demand Lighting Is Inoperative E1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8660 E2 - E4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8661 E4 F1 - F2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8662 F2 - F3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Page 8663 Courtesy Lamp: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Page 8664 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations View 151-23 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 8669 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 8670 Daytime Running Lamp Control Unit: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations View 151-23 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 8674 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 8675 Daytime Running Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 8676 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service Precautions > Technician Safety Information > Page 8688 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service Precautions > Page 8689 Fog/Driving Lamp Bulb: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8693 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8694 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8695 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8696 Fog/Driving Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8697 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 8701 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 8702 Fog/Driving Lamp Switch: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations View 151-17 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 8707 Hazard Warning Flasher: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 8711 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 rearward 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Technician Safety Information > Page 8717 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Page 8718 Headlamp Bulb: Service and Repair 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. Disconnect the headlamp electrical connector. NOTE: Make sure that the headlamp switch and the ignition switch are in the OFF position. 2. Remove the rubber boot. 3. Depress the retainer clip and position aside. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Page 8719 4. Remove the bulb. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Application and ID Headlamp Control Module: Application and ID For further information concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection Headlamp Dimmer Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 8726 Dimmer Switch, Interior Lamps Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 8730 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 8731 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 8732 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 8733 Headlamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 8734 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 8738 Main Light Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 8739 Headlamp Switch, Exterior Lamps Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8744 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8745 View 151-39 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8746 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8747 Horn Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8748 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Application and ID Interior Lighting Module: Application and ID For further information concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8756 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8757 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8758 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8759 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8760 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8761 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8762 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8763 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8764 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8765 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8766 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8767 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8768 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8769 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8770 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8771 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8772 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8773 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8774 License Plate Lamp: Connector Views Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8775 Diagram 92-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 8776 License Plate Lamp: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Parking Lamp; Testing and Inspection. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 8777 License Plate Lamp: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8785 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8786 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8787 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8788 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8789 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8790 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8791 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8792 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8793 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8794 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8795 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8796 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8797 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8798 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8799 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8800 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8801 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8802 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8803 Diagram 92-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 8804 Marker Lamp: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 8809 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 8810 View 151-39 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 8811 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 8812 Parking Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 8813 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 8818 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 8819 Daytime Running Lamp Control Unit: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations View 151-23 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 8823 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 8824 Daytime Running Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 8825 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8829 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8830 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8831 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8832 Fog/Driving Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8833 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 8840 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 8841 View 151-37 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 8842 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 8843 Headlamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 8844 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8848 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8849 View 151-39 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8850 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8851 Horn Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8852 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 8859 Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 8860 View 151-39 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 8861 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 8862 Parking Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 8863 Relay - Micro ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations View 151-4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Transmission Range Sensor Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Transmission Range Sensor > Page 8870 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Brake Pedal Position Switch Brake Pedal Position Switch: Description and Operation Brake Pedal Position Switch Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Brake Pedal Position Switch > Page 8876 Brake Pedal Position Switch: Description and Operation Brake Pressure Applied Brake Deactivator Switch Brake Pressure Applied Brake Deactivator Switch The Brake Pressure Applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, witch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Page 8877 Brake Pedal Position Switch: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 8884 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 8885 Fog/Driving Lamp Switch: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 8889 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 rearward 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection Headlamp Dimmer Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 8893 Dimmer Switch, Interior Lamps Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 8897 Main Light Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 8898 Headlamp Switch, Exterior Lamps Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the upper steering column shroud. 3. Remove the lower steering column shroud. 1. Remove the screws. 2. Remove the lower steering column shroud. 4. Remove the multifunction switch. 1. Disconnect the electrical connector. 2. Remove the screws. 3. Remove the multifunction switch. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8906 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8907 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8908 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8909 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8910 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8911 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8912 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8913 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8914 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8915 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8916 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8917 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8918 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8919 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8920 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8921 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8922 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8923 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8924 Diagram 92-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 8925 Tail Lamp: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Parking Lamp; Testing and Inspection. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 8926 Tail Lamp: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8931 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8932 Diagram 3-3 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. See: Locations/Component Locations/Component Location Views 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. Component Identification Numbers (6) Each component on each diagram has a component identification number (i.e. A166, A205, etc.) located to the upper right hand side of the component. By finding this number or the component name on one of the A-Z Component Lists, a brief description of the component's location can be found. See: Locations/Component Locations/A-Z Component List Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8933 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8934 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. See: Locations Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views "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. See: Diagrams/Connector Views 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. Symbols and Wire Color Code Identification Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8935 Symbols Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8936 Symbols Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8937 Symbols Part 3 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8938 Symbols Part 4 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8939 Symbols Part 5 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8940 Systems Overview Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8941 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8942 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8943 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8944 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8945 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8946 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8947 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8948 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8949 Diagram 95-1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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. See: Pinpoint Tests 3. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 21 (10 A) - 16 (10 A) ^ 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8952 Symptom Chart Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8953 Trailer Lamps: Pinpoint Tests Connector Circuit Reference Refer to Vehicle/Diagrams for schematic and connector information. Z1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8954 AA1 - AA2 AC1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8955 AC1 AD1 AE1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8956 AE1 - AE2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8957 73III Automotive Meter Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Page 8958 73III Automotive Meter Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations View 151-17 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 8963 Turn Signal Flasher: Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the upper steering column shroud. 3. Remove the lower steering column shroud. 1. Remove the screws. 2. Remove the lower steering column shroud. 4. Remove the multifunction switch. 1. Disconnect the electrical connector. 2. Remove the screws. 3. Remove the multifunction switch. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 8976 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 8977 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 8978 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 8979 Heated Glass Element Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 8980 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams > Page 8984 Heated Glass Element Switch: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 8989 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 8990 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 8991 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 8992 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 8993 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Part 1 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 8998 Part 2 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 8999 View 151-36 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 9000 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 9001 Heated Glass Element Relay: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 9002 Relay - Mini ISO Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 9007 Heated Glass Element Switch: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 9012 Power Window Switch: Diagrams Window Adjust Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 9013 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 9016 Master Window Control Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 9017 Master Window Control Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 9018 Power Window Switch: Testing and Inspection Window Adjust Switch Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 9019 Window Adjust Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 9020 Power Window Switch: Service and Repair REMOVAL NOTE: The removal and installation procedures for all window control switches are similar. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Left Front Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Left Front > Page 9027 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch > Page 9032 Power Window Switch: Diagrams Window Adjust Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch > Page 9033 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 9036 Master Window Control Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 9037 Master Window Control Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 9038 Power Window Switch: Testing and Inspection Window Adjust Switch Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 9039 Window Adjust Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 9040 Power Window Switch: Service and Repair REMOVAL NOTE: The removal and installation procedures for all window control switches are similar. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Front Door Glass Top Run > Page 9045 Window Frame: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Front Door Glass Top Run > Page 9046 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Page 9051 9. Remove the front door window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair 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. Disconnect the two liftgate window glass cylinders. 1 Slide the spring retainer to the end of the socket. 2 Disconnect the socket from the ball stud. NOTE: An assistant may be needed to carry out this step. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 9055 6. Remove the two liftgate window glass hinge nuts. NOTE: An assistant may be needed to carry out this step. INSTALLATION 1. To install, reverse the removal procedure. ^ Transfer components as necessary. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair Quarter Window Glass: Service and Repair 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. 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. 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 9059 2. 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. CAUTION: Do not scratch the pinch weld area. 3. 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. 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. 4. Clean the inside of the quarter glass surface with alcohol-free cleaner, making sure the ceramic coated area is clean. 5. Apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the glass surface to urethaned. NOTE: Wipe off the glass prep immediately after each application because it flash dries. 6. Apply Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C 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. 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. NOTE: Use caution when applying urethane adhesive. Apply to the outside edges of locating tabs on the glass surface. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 9060 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 9068 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 9072 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 9073 2 Remove the nuts. INSTALLATION All vehicles 1. To install, reverse the removal procedure. ^ Cycle the door glass to make sure of correct window glass engagement. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician Safety Information > Page 9078 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 9079 Windshield: Service and Repair 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 9080 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 9081 11. Using the special tool, cut the urethane adhesive from the windshield glass starting at the top center and work toward the bottom corners. NOTE: Lubricate the urethane adhesive with water to aid the special tool when cutting. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 9082 2. 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. CAUTION: Do not scratch the pinch weld area. 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. If installing a new windshield glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the glass surface to be urethaned. NOTE: Wipe off the glass prep immediately after each application because it flash dries. 7. If installing a new windshield, apply Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was prepped in the pervious step. Allow five minutes to dry. 8. Apply foam dam meeting Ford specification EBS-M3G137-A to the bottom of the windshield glass. 9. Cut the urethane adhesive applicator tip to specification. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 9083 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. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 9084 ^ If equipped, connect the electrical connector. 2 Install the screws. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 9085 Special Tool(s) Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9095 Windshield Washer Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9096 Wiper/washer Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9097 Windshield Washer Switch: Service and Repair REMOVAL 1. Remove the steering column shroud. NOTE: The windshield wiper/washer switch is part of the multifunction switch assembly. 2. Remove the screws. 3. Remove the windshield wiper/washer switch. 1 Disconnect the electrical connector. 2 Remove the windshield wiper/washer switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9101 Wiper Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9102 Wiper/washer Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9103 Wiper Switch: Service and Repair REMOVAL 1. Remove the steering column shroud. NOTE: The windshield wiper/washer switch is part of the multifunction switch assembly. 2. Remove the screws. 3. Remove the windshield wiper/washer switch. 1 Disconnect the electrical connector. 2 Remove the windshield wiper/washer switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair Windshield Washer Hose: Service and 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. 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. NOTE: In difficult cases, clamping may be required. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service Precautions > Technician Safety Information > Page 9115 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 REMOVAL 1. Remove the RH front wheel and tire assembly. 2. Remove the RH front splash shield. 3. Remove the windshield washer pump. 1 Disconnect the electrical connector. 2 Disconnect the hose. 3 Remove the windshield washer pump. 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. INSTALLATION 1. To install, reverse the removal procedure. ^ Fill the windshield washer reservoir with Ultra-Clear Windshield Washer Concentrate C9AZ-19550-AC or BC or equivalent meeting Ford specification ESR-M17P5-A. WARNING: WINDSHIELD WASHER SOLUTION CONTAINS METHANOL, WHICH IS POISONOUS. OBSERVE ALL CAUTIONS AND WARNINGS INDICATED ON THE LABEL OF THE WASHER SOLUTION CONTAINER. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Windshield Washer Pump > Page 9118 Windshield Washer Pump: Service and Repair Rear Window Washer Pump REMOVAL 1. Remove the RH front wheel and tire assembly. 2. Remove the RH front splash shield. 3. Remove the windshield washer pump. 1 Disconnect the electrical connector. 2 Disconnect the hose. 3 Remove the windshield washer pump. 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. INSTALLATION 1. To install, reverse the removal procedure. ^ Fill the windshield washer reservoir with Ultra-Clear Windshield Washer Concentrate C9AZ-19550-AC or BC or equivalent meeting Ford specification ESR-M17P5-A. 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. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Windshield Washer Pump > Page 9119 Windshield Washer Pump: 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. Position the windshield washer reservoir aside. 1 Remove the bolts. 2 Position the windshield washer reservoir aside. 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. 4. Remove the windshield washer reservoir. 1 Disconnect the electrical connectors. 2 Disconnect the hoses. 3 Remove the windshield washer reservoir. INSTALLATION 1. To install, reverse the removal procedure. ^ Fill the windshield washer reservoir with Ultra-Clear Windshield Washer Concentrate C9AZ-19550-AC or BC or equivalent meeting Ford specification ESR-M17P5-A. 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. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service Precautions > Technician Safety Information > Page 9124 Windshield Washer Reservoir: Vehicle Damage Warnings CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service Precautions > Page 9125 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Remove the right front wheel and tire assembly. 2. Remove the right front splash shield. 3. Position the windshield washer reservoir aside. 1 Remove the bolts. 2 Position the windshield washer reservoir aside. 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. 4. Remove the windshield washer reservoir. 1 Disconnect the electrical connectors. 2 Disconnect the hoses. 3 Remove the windshield washer reservoir. INSTALLATION 1. To install, reverse the removal procedure. ^ Fill the windshield washer reservoir with Ultra-Clear Windshield Washer Concentrate C9AZ-19550-AC or BC or equivalent meeting Ford specification ESR-M17P5-A. 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. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9129 Windshield Washer Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9130 Wiper/washer Switch Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9131 Windshield Washer Switch: Service and Repair REMOVAL 1. Remove the steering column shroud. NOTE: The windshield wiper/washer switch is part of the multifunction switch assembly. 2. Remove the screws. 3. Remove the windshield wiper/washer switch. 1 Disconnect the electrical connector. 2 Remove the windshield wiper/washer switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 9140 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 9146 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 location. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Windshield Wiper Blade and Pivot Arm Adjustment > Page 9149 Wiper Arm: Adjustments 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front Wiper Arm: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 9152 Wiper Arm: Service and Repair 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 location. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Adjustments > Windshield Wiper Blade and Pivot Arm Adjustment > Page 9157 Wiper Blade: Adjustments 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Application and ID Wiper Control Module: Application and ID For further information concerning Multifunction Generic Electronic Modules, please see Accessories and Optional Equipment, General Module. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 9169 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 9175 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Windshield Wiper Motor Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Windshield Wiper Motor > Page 9178 Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 9179 Wiper Motor: Testing and Inspection 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. 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) 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 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 9182 Wiper Motor: Service and Repair 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. 5. Remove the rear wiper motor plastic cover. Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 9183 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 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9187 Wiper Switch: Testing and Inspection Introduction To Component Testing Ford Escape 4wd Workshop Manual (V6-182 3.0L VIN 1 SFI (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9188 Wiper/washer Switch