Ford - Escape 4wd - Workshop Manual - 2009 - 2009

Factory Workshop Manual Make Ford Model Escape 4wd Engine and year L4-2.5L Hybrid (2009) 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0560 - P0564, ( P0561 P0562 P0563 0560 0561 0562 0563 0564 ) > System Information > System Diagnosis > P0562 P0560 - P0564: Testing and Inspection P0562 PCM For diagnosis of all P codes - See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures TCM For diagnosis of all P codes - See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0560 - P0564, ( P0561 P0562 P0563 0560 0561 0562 0563 0564 ) > System Information > System Diagnosis > P0562 > Page 9 P0560 - P0564: Testing and Inspection P0563 PCM For diagnosis of all P codes - See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures TCM For diagnosis of all P codes - See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0A00-P0AZZ > P0A25 - P0A29, ( P0A26 P0A27 P0A28 0A25 0A26 0A27 0A28 0A29 ) > System Information > System Diagnosis > P0A27 P0A25 - P0A29: Testing and Inspection P0A27 PCM For diagnosis of all P codes - See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures TBCM For diagnosis of all P codes - See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2800-P28ZZ > P2805 - P2809, ( P2806 P2807 P2808 2805 2806 2807 2808 2809 ) > System Information > System Diagnosis > P2806 P2805 - P2809: Testing and Inspection P2806 PCM For diagnosis of all P codes - See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures TCM For diagnosis of all P codes - See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 38 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 39 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 44 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 45 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: All Technical Service Bulletins SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 55 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 56 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 61 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 62 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) > Page 65 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) Communications Control Module: Diagrams Accessory Protocol Interface Module (APIM) Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 68 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 69 Communications Control Module: Diagrams Audio Control Module (ACM) Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 70 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 71 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures Communications Control Module: Procedures Accessory Protocol Interface Module (APIM) Software Level Check Accessory Protocol Interface Module (APIM) Software Level Check NOTE: This procedure applies to checking the Accessory Protocol Interface Module (APIM) software level. To program the APIM, refer to Accessory Protocol Interface Module (APIM) Programming in Information Bus. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning/Accessory Protocol Interface Module (APIM) Programming 1. Turn the Audio Control Module (ACM) on. 2. Connect the scan tool to the Data Link Connector (DLC). 3. Connect one end of the Universal Serial Bus (USB) male-A to male-A cable to the scan tool. 4. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 5. From the technician service publication website, run On-Line Automotive Service Information System (OASIS) using Quick Start or by manually entering the Vehicle Identification Number (VIN). 6. From the OASIS tab, select the "Sync/APIM" bullet. 7. Select the "Read APIM" button to verify the current Accessory Protocol Interface Module (APIM) software level. - The display shows both the Vehicle Interface Processor (VIP) and Consumer Interface Processor (CIP) software levels. 8. The scan tool displays the following information: - Last Recorded State - Hardware VIN: vehicle identification number associated with the current APIM - Installed date: date the APIM was installed - Radio: currently identified ACM in the vehicle - HW Part No.: APIM hardware part number - Un-installed date: date (if any) the APIM was uninstalled - S/N: APIM serial number - Last Recorded State - Software Date/Time: date and time of last recorded software installation - VIP: VIP software that was installed at that time - CIP: CIP software that was installed at that time Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 74 - Description: a description of the content of the software revision - History - Software Date/Time: date and time of any recorded software installation - VIP: VIP software that was installed at that time - CIP: CIP software that was installed at that time - Description: a description of the content of the software revision - Available Software for Programming Select: allows the software package to be selected - Lineage: the original software release, if the software available is a revision - VIP: VIP software level that is available with the selection - CIP: CIP software level that is available with the selection - Description: a description of the content of the software revision 9. Click a CIP software level to view the device compatibility list associated with the CIP software level, if desired. 10. To exit the APIM software level check, disconnect the scan tool from the DLC and the USB port, or exit the OASIS screen. Audio Control Module (ACM) Self-Diagnostic Mode Audio Control Module (ACM) Self-Diagnostic Mode Audio Systems Without Navigation 1. Turn the Audio Control Module (ACM) on. 2. Operate the audio system in radio tuner (AM/FM) mode. 3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins. - The display indicates each speaker as it is tested. 4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after step 3 by turning the ACM off. Before the speaker walk test is complete, carry out any of the following actions: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 75 5. To exit the self-diagnostic mode, turn the ACM off. Satellite Digital Audio Receiver System (SDARS) Module Electronic Serial Number (ESN) Retrieval - Vehicles Without Navigation 1. Operate the audio system in satellite radio mode. 2. Press and hold the AUX button and preset button 1, simultaneously. - The Satellite Digital Audio Receiver System (SDARS) module Electronic Serial Number (ESN) displays on the screen. 3. Record the SDARS module ESN. 4. Turn the audio system off. Navigation Audio System 1. Turn the Audio Control Module (ACM) on. 2. Operate the audio system in radio tuner (AM/FM) mode. 3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins. - The display indicates each speaker as it is tested. 4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after this step, or by allowing the speaker walk test to complete on its own. Before the speaker walk test is complete, press the "End Test" selection. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 76 5. The following tests are available through the "BEZEL DIAGNOSTICS" menu: 6. To exit the self-diagnostic mode, press the "Exit Diagnostics" selection from the "BEZEL DIAGNOSTICS" menu. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 77 Communications Control Module: Removal and Replacement Audio Control Module (ACM) Audio Control Module (ACM) All Except Navigation Navigation Removal and Installation All vehicles 1. NOTE: Module configuration is only required if a new ACM is being installed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 78 Upload the ACM configuration to the scan tool. 2. Remove the middle instrument panel center finish panel. 3. Remove the 4 ACM screws. - To install, tighten to 2 Nm (18 lb-in) (navigation). - To install, tighten to 1 Nm (9 lb-in) (all except navigation). Navigation 4. Disconnect the antenna and electrical connectors. All except navigation 5. If equipped, remove the 4 screws and the ACM side support brackets. 6. NOTE: Only carry out this step if installing a new ACM. Remove the 2 ACM brackets. All vehicles 7. Remove the ACM. 8. To install, reverse the removal procedure. - Download the configuration information to the ACM. Accessory Protocol Interface Module (APIM) Accessory Protocol Interface Module (APIM) Removal and Installation 1. NOTE: It is necessary to record the current Accessory Protocol Interface Module (APIM) software and hardware level when a new APIM is being installed to make sure that the new component is the same version as the component being replaced. Retrieve and record the current APIM software and hardware level. For additional information, refer to Accessory Protocol Interface Module (APIM) Software Level Check See: Procedures/Accessory Protocol Interface Module (APIM) Software Level Check. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 79 2. Remove the floor console. 3. Disconnect the APIM electrical connector and the Universal Serial Bus (USB) cable electrical connector. 4. Remove the 3 screws and the APIM. - Slide the APIM upward to release the locator clips. 5. To install, reverse the removal procedure. - If a new APIM is being installed, program the APIM to the correct software level. Universal Serial Bus (USB) Cable and Port Universal Serial Bus (USB) Cable and Port Floor Console Trim Panels Universal Serial Bus (USB) Port and Cable Removal and Installation Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 80 NOTE: The original equipment Universal Serial Bus (USB) port and cable is part of the wiring harness. It can only be serviced by overlaying a new USB port and cable. 1. Remove the transmission selector level bezel by pulling straight up. 2. NOTE: Open the floor console storage bin door. Remove the floor console finish panel by pulling straight up. - Disconnect the electrical connector, if necessary. 3. Remove the center instrument panel lower panel by pulling straight back. - Disconnect the electrical connectors. 4. Remove the USB cable and port. - Disconnect the cable from the Accessory Protocol Interface Module (APIM). - Cut the USB port and cable ends and secure them to prevent NVH concerns. 5. To install, reverse the removal procedure. - Secure the new USB port and cable, as necessary, to prevent NVH concerns. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 89 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 90 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 95 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 96 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 97 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 98 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 99 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 100 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 101 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 102 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 103 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 104 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 105 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 111 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 112 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 117 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 118 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 119 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 120 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 121 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 122 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 123 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 124 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 125 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 126 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 127 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 132 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 133 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 139 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 140 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > Customer Interest for Entertainment System Control Module: > 09-11-9 > Jun > 09 > Navigation Radio - Time Displays Twice In CD Mode Entertainment System Control Module: Customer Interest Navigation Radio - Time Displays Twice In CD Mode TSB 09-11-9 06/15/09 NAVIGATION RADIO - WHEN ON IN CD MODE - TIME DISPLAYS TWICE IN THE FDIM FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape and Mariner vehicles equipped with Navigation radio, may exhibit a concern when turning on the audio unit in CD mode. The time will display twice in the Front Display lnter[ace Module (FDIM), both in the center and in the upper right hand corner. Normal operation should be the time displaying in the center of the FDIM when the Navigation unit is off and in the upper right hand corner of the FDIM when the Navigation unit is on. ACTION Reprogram the Front Display Interface Module (FDIM) module to the latest calibration using IDS release 61.04 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration and IDS patch files may also be obtained at the website. 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 091109A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Reprogram The FDIM (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 19C116 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Entertainment System Control Module: > 09-11-9 > Jun > 09 > Navigation Radio - Time Displays Twice In CD Mode Entertainment System Control Module: All Technical Service Bulletins Navigation Radio - Time Displays Twice In CD Mode TSB 09-11-9 06/15/09 NAVIGATION RADIO - WHEN ON IN CD MODE - TIME DISPLAYS TWICE IN THE FDIM FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape and Mariner vehicles equipped with Navigation radio, may exhibit a concern when turning on the audio unit in CD mode. The time will display twice in the Front Display lnter[ace Module (FDIM), both in the center and in the upper right hand corner. Normal operation should be the time displaying in the center of the FDIM when the Navigation unit is off and in the upper right hand corner of the FDIM when the Navigation unit is on. ACTION Reprogram the Front Display Interface Module (FDIM) module to the latest calibration using IDS release 61.04 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration and IDS patch files may also be obtained at the website. 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 091109A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Reprogram The FDIM (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 19C116 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 162 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 163 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 169 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 170 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 179 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 180 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 186 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 187 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 191 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 192 Parking Assist Control Module: Service and Repair Parking Aid Module (PAM) Removal and Installation 1. NOTE: Module configuration is only required if a new Parking Aid Module (PAM) is being installed. Upload the PAM configuration information to the scan tool. 2. Remove the RH rear quarter trim panel. 3. If replacing the parking aid speaker only, proceed as follows: - Disconnect the electrical connector. - Disengage the clips. - Remove the parking aid speaker. 4. If replacing the PAM, proceed as follows: - Disconnect the electrical connector. - Remove the 2 screws. - Remove the PAM. 5. To install, reverse the removal procedure. - Download the configuration information to the PAM. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair Seat Heater Control Module: Service and Repair Seat - Exploded View, Front Seat Backrest - Front NOTE: Driver seat shown, passenger seat similar. Seat Cushion - Driver NOTE: Power seat track shown, manual seat track similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Page 197 Seat Cushion - Front, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Page 198 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Locations > Heated Seats Relay Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Locations > Heated Seats Relay > Page 203 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams > Heated Seat Relay, Driver Seat Heater Relay: Diagrams Heated Seat Relay, Driver Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams > Heated Seat Relay, Driver > Page 206 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams > Heated Seat Relay, Driver > Page 207 Seat Heater Relay: Diagrams Heated Seat Relay, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams > Heated Seat Relay, Driver > Page 208 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 212 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 220 Electronic Brake Control Module: Diagrams Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 221 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 222 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module NOTE: Non-hybrid vehicles shown, hybrid vehicles similar. Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: Do not swap ABS modules between vehicles, the ABS module and the Hydraulic Control Unit (HCU) are calibrated as an assembly. All vehicles 1. Remove the HCU. For additional information, refer to Hydraulic Control Unit (HCU) - Hybrid See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair. Non-hybrid vehicles Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 223 2. Remove the Hydraulic Control Unit (HCU) See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair. For additional information, refer to Hydraulic Control Unit (HCU) See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair. 3. Remove the jumper tube assembly bracket nut. - To install, tighten to 9 Nm (80 lb-in). 4. Disconnect the jumper tubes fittings from the HCU and remove the jumper tube assembly. - To install, tighten to 15 Nm (133 lb-in). All vehicles 5. Remove the 4 ABS module screws and the ABS module. - To install, tighten to 2 Nm (18 lb-in). 6. To install, reverse the removal procedure. 7. Configure the ABS module. 8. Calibrate the ABS module. - For non-hybrid vehicles, carry out the IVD Initialization sequence following the scan tool directions. - For hybrid vehicles, carry out the Multi-Calibration routine following the scan tool directions. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Vacuum Pump Relay, Brakes > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Auxiliary Water Pump Relay > Component Information > Locations > M/E Coolant Pump Relay Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Auxiliary Water Pump Relay > Component Information > Locations > M/E Coolant Pump Relay > Page 232 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Fan Control Relay 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Fan Control Relay 1 > Page 237 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Fan Control Relay 1 > Page 238 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Auxiliary Water Pump Relay > Component Information > Locations > M/E Coolant Pump Relay Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Auxiliary Water Pump Relay > Component Information > Locations > M/E Coolant Pump Relay > Page 244 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 251 Compressor Clutch Relay: Description and Operation Air Conditioning (A/C) Clutch Relay The A/C clutch relay (may be referred to as the wide open throttle (WOT) A/C cutoff relay) is wired normally open. There is no direct electrical connection between the A/C switch or electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives a signal indicating that A/C is requested. When A/C is requested, the PCM checks other A/C related inputs that are available. If these inputs indicate A/C operation is OK, and the engine conditions are OK (coolant temperature, engine RPM, throttle position), the PCM grounds the wide open throttle A/C cut-off (WAC) output, closing the relay contacts and sending voltage to the A/C clutch. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 11-3-9 > Mar > 11 > A/C - Poor Cooling Performance Control Module HVAC: Customer Interest A/C - Poor Cooling Performance TSB 11-3-9 03/15/11 HYBRID - LACK OF A/C COOLING FORD: 2009 Escape MERCURY: 2009 Mariner ISSUE Some 2009 Escape and Mariner Hybrid vehicles equipped with electronic automatic temperature control (EATC) may exhibit a lack of A/C cooling. Low battery voltage during a previous vehicle start may cause the heating ventilation air conditioning (HVAC) module to function in conventional gasoline mode instead of hybrid vehicle mode. ACTION Follow Service Procedure to correct the condition. SERVICE PROCEDURE 1. To determine if the HVAC control module has defaulted to gasoline mode, first turn off the A/C and Recirculated Air buttons on the HVAC control head. 2. Turn off the HVAC control head. 3. Press the ECON button, the yellow led will light up. 4. Does the A/C and recirculated air buttons also light up when the ECON button is pressed? a. Yes - HVAC module is in gasoline mode, proceed to Step 5. b. No - HVAC module is not in gas mode, this procedure does not apply. 5. Reprogram the HVAC module to the latest calibration using IDS release 71.00 and higher. This new calibration is not included in the VCM 2010.11 DVD. Calibration files may also be obtained at the website. 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 110309A 2009 Escape and Mariner 0.3 Hr. Hybrid: Reprogram The HAVC Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19980 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11-3-9 > Mar > 11 > A/C - Poor Cooling Performance Control Module HVAC: All Technical Service Bulletins A/C - Poor Cooling Performance TSB 11-3-9 03/15/11 HYBRID - LACK OF A/C COOLING FORD: 2009 Escape MERCURY: 2009 Mariner ISSUE Some 2009 Escape and Mariner Hybrid vehicles equipped with electronic automatic temperature control (EATC) may exhibit a lack of A/C cooling. Low battery voltage during a previous vehicle start may cause the heating ventilation air conditioning (HVAC) module to function in conventional gasoline mode instead of hybrid vehicle mode. ACTION Follow Service Procedure to correct the condition. SERVICE PROCEDURE 1. To determine if the HVAC control module has defaulted to gasoline mode, first turn off the A/C and Recirculated Air buttons on the HVAC control head. 2. Turn off the HVAC control head. 3. Press the ECON button, the yellow led will light up. 4. Does the A/C and recirculated air buttons also light up when the ECON button is pressed? a. Yes - HVAC module is in gasoline mode, proceed to Step 5. b. No - HVAC module is not in gas mode, this procedure does not apply. 5. Reprogram the HVAC module to the latest calibration using IDS release 71.00 and higher. This new calibration is not included in the VCM 2010.11 DVD. Calibration files may also be obtained at the website. 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 110309A 2009 Escape and Mariner 0.3 Hr. Hybrid: Reprogram The HAVC Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19980 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 265 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 266 Control Module HVAC: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 267 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 08-23-12 > Nov > 08 > Temperature Display - Toggles From Fahrenheit To Celsius Instrument Panel Control Module: Customer Interest Temperature Display - Toggles From Fahrenheit To Celsius TSB 08-23-12 11/24/08 FRONT DISPLAY INTERFACE MODULE (FDIM) - OUTSIDE TEMPERATURE DISPLAY TOGGLES BETWEEN FAHRENHEIT/CELSIUS FORD: 2008-2009 Escape Hybrid, Escape MERCURY: 2008-2009 Mariner Hybrid, Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles may exhibit an outside temperature display in the FDIM that toggles between Fahrenheit and Celsius. ACTION Reprogram the Instrument Cluster module to the latest calibration using IDS release 57.9 and higher with patch 13 or 58.2 and higher. This new calibration is not included in the VCM 2008.11 DVD. Calibration and IDS patch files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 082312A 2008-2009 Escape, 0.3 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Reprogram The Instrument Cluster, Authorization Decal Not Required.(Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 08-23-12 > Nov > 08 > Temperature Display - Toggles From Fahrenheit To Celsius Instrument Panel Control Module: All Technical Service Bulletins Temperature Display - Toggles From Fahrenheit To Celsius TSB 08-23-12 11/24/08 FRONT DISPLAY INTERFACE MODULE (FDIM) - OUTSIDE TEMPERATURE DISPLAY TOGGLES BETWEEN FAHRENHEIT/CELSIUS FORD: 2008-2009 Escape Hybrid, Escape MERCURY: 2008-2009 Mariner Hybrid, Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles may exhibit an outside temperature display in the FDIM that toggles between Fahrenheit and Celsius. ACTION Reprogram the Instrument Cluster module to the latest calibration using IDS release 57.9 and higher with patch 13 or 58.2 and higher. This new calibration is not included in the VCM 2008.11 DVD. Calibration and IDS patch files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 082312A 2008-2009 Escape, 0.3 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Reprogram The Instrument Cluster, Authorization Decal Not Required.(Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 289 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 290 Interior Lighting Module: Service and Repair Ambient Lighting Module Removal and Installation 1. Remove the center console finish panel. 2. Remove the 2 screws and the ambient lighting module. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 298 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair Power Distribution Module: Service and Repair Smart Junction Box (SJB) Removal NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new Smart Junction Box (SJB) after installation. In the event that As-Built data is required (SJB will not communicate), all Remote Keyless Entry (RKE) devices must be programmed to the new SJB. A minimum of 2 RKE devices are necessary to complete the configuration and turn off the flashing interior lights. The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. NOTE: The steps included in the SJB removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered in a manufacturing mode with 7 pre-set DTCs related to the TPMS. To clear the DTCs, successful configuration of the SJB must occur, followed by successful TPMS sensor training, and a successful self-test. The DTCs are as follows: - B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) - B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is necessary only if the SJB is being replaced. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 302 Upload the module configuration information from the SJB. 2. Remove the transmission selector lever bezel from the floor console finish panel. 3. Remove the floor console SJB cover. 4. Remove the floor console finish panel. 5. Disconnect the 7 electrical connectors. 6. Remove the 2 bolts and the SJB. Installation 1. Install the SJB. - Install the 2 bolts. - Connect the 7 electrical connectors. 2. Install the transmission selector lever bezel into the floor console finish panel. 3. NOTE: If the SJB was not replaced, this is the last step that is necessary. Install the floor console SJB cover. 4. NOTE: When successful, this step provides the calibration necessary for the SJB operation and clears DTCs B2477 and B106D. The clearing of these DTCs indicates the calibration data has been successfully downloaded to the new SJB. NOTE: The RKE transmitter portion of the Integrated Keyhead Transmitter (IKT) key is automatically transferred during Programmable Module Installation (PMI). Passive Anti-Theft System (PATS) programming is not necessary. If As-Built data is required during PMI, all remote transmitters (IKT or fob) must be programmed to the new SJB. Cycling the ignition to run for 6 seconds with each IKT will program the RKE function of the IKT key. NOTE: DTC B2276 may be set, indicating there are less than 2 transmitters programmed to the SJB. 5. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the SJB has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 6. NOTE: DTC C2780 will not clear if any other DTCs are present in the SJB. When successful, this step will clear DTC C2780. Carry out the SJB self-test (must include an on-demand self-test) and then repeat the self-test to confirm all DTCs have been cleared. 7. Rotate the instrument panel dimmer switch from the full dim position to the dome ON position. This will make sure that all displays are visible under all lighting conditions. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 310 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 311 Relay Box: Locations Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 312 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 313 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 316 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 317 Relay Box: Diagrams Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 318 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 319 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 320 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 321 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 322 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) Relay Box: Application and ID Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 325 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 326 Relay Box: Application and ID Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 327 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation Torque-Based Electronic Throttle Control (ETC) Overview The torque-based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. Electronic Throttle Body (ETB) The ETB has the following characteristics: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires two wires). - An internal spring is used to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore. This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. - The required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. - There is one reference voltage and one signal return circuit between the PCM and the ETB. The reference voltage and the signal return circuits are shared with the reference voltage and signal return circuits used by the accelerator pedal position (APP) sensor. There are also two throttle position (TP) signal circuits for redundancy. The redundant TP signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor For additional information on the APP sensor, refer to Engine Control Components See: Powertrain Management/Computers and Control Systems/Description and Operation/Engine Control Components. Electronic Throttle Control (ETC) System Strategy The torque-based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize the fuel control while delivering the requested torque. The ETC monitor system is distributed across two processors within the PCM: the main powertrain control processor unit (CPU) and a separate monitoring processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, appropriate corrective action is taken. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 333 ECT System Failure Mode Effects Management (FMEM) Electronic Throttle Monitor Operation a Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Accelerator Pedal Position (APP) and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check a Correlation and range/performance - sensor disagreement between processors internal to the PCM. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions for additional DTC information. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 334 Throttle Position (TP) Sensor Check a Correlation and range/performance - sensor disagreement between processors internal to the PCM, TP inconsistent with requested throttle plate position. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions for additional DTC information. Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check a Note: For all DTCs, in addition to the MIL, the powertrain malfunction indicator (wrench) is on for the concern that caused the FMEM action. Monitor execution is continuous. Monitor false detection duration is less than 5 seconds to register a concern. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Engine Control Module: Customer Interest Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 343 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0442/P0456/P1450 TSB 10-1-3 02/01/10 HYBRID ONLY - DTCS P0442, P0456 OR P1450 - BUILT ON OR BEFORE 4/6/2009 FORD: 2010 Fusion 2009 Escape MERCURY: 2010 Milan 2009 Mariner This article supersedes TSB 09-9-9 to add a production fix date. ISSUE Some 2009 Escape Hybrid, Mariner Hybrid, 2010 Fusion Hybrid and Milan Hybrid vehicles built on or before 4/6/2009 may exhibit a malfunction indicator light (MIL) accompanied by diagnostic trouble code (DTC) P0442, P0456 or P1450. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Follow the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostic procedures for any DTC code that may be present to ensure the Evaporative Emissions (EVAP) system is functioning properly. 2. When performing EVAP diagnostics on Escape Hybrid and Mariner Hybrid vehicles, the ambient temperature must be greater than 32 °F (0 °C) and the heating ventilation air conditioning (HVAC) system should be set to Defrost. This will provide continuous gasoline engine operation. 3. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 60.11 and higher or 61.01 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 100103A 2010 Fusion Hybrid/Milan 0.3 Hr. Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) 100103A 2009 Escape 0.3 Hr. Hybrid/Mariner Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 348 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Engine Control Module: All Technical Service Bulletins Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 354 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0442/P0456/P1450 TSB 10-1-3 02/01/10 HYBRID ONLY - DTCS P0442, P0456 OR P1450 - BUILT ON OR BEFORE 4/6/2009 FORD: 2010 Fusion 2009 Escape MERCURY: 2010 Milan 2009 Mariner This article supersedes TSB 09-9-9 to add a production fix date. ISSUE Some 2009 Escape Hybrid, Mariner Hybrid, 2010 Fusion Hybrid and Milan Hybrid vehicles built on or before 4/6/2009 may exhibit a malfunction indicator light (MIL) accompanied by diagnostic trouble code (DTC) P0442, P0456 or P1450. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Follow the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostic procedures for any DTC code that may be present to ensure the Evaporative Emissions (EVAP) system is functioning properly. 2. When performing EVAP diagnostics on Escape Hybrid and Mariner Hybrid vehicles, the ambient temperature must be greater than 32 °F (0 °C) and the heating ventilation air conditioning (HVAC) system should be set to Defrost. This will provide continuous gasoline engine operation. 3. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 60.11 and higher or 61.01 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 100103A 2010 Fusion Hybrid/Milan 0.3 Hr. Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) 100103A 2009 Escape 0.3 Hr. Hybrid/Mariner Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 359 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 360 Engine Control Module: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 361 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 362 Engine Control Module: Diagrams Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 363 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 364 Part 3 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 365 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 366 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 367 Part 3 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 368 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 369 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory (EEPROM) WARNING: THIS VEHICLE IS EQUIPPED WITH HIGH VOLTAGE CABLES, COMPONENTS, AND WIRING. THE HIGH VOLTAGE WARNING LABELS CONTAINING THE HIGH VOLTAGE SYMBOL ARE LOCATED ON EACH HIGH VOLTAGE COMPONENT. HIGH VOLTAGE CABLES AND WIRING ARE ORANGE IN COLOR. CERTIFIED RUBBER INSULATING GLOVES AND A FACE SHIELD MUST BE WORN WHEN WORKING WITH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING. THE IGNITION KEY MUST BE CYCLED TO THE OFF POSITION FOR A MINIMUM OF 5 MINUTES, AND THE HIGH VOLTAGE TRACTION BATTERY SERVICE DISCONNECT PLUG PLACED IN THE SERVICING/SHIPPING POSITION BEFORE DISCONNECTING THE HIGH VOLTAGE CABLES. DO NOT DISCONNECT, DISABLE, OR TOUCH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING DURING THE MODULE REPROGRAMMING PROCEDURE BECAUSE HIGH VOLTAGE IS PRESENT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH. Description Flash electrically erasable programmable read only memory (EEPROM) is contained in an integrated circuit internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block must be programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate diagnostic trouble code (DTC) P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. Failure to carry out this procedure correctly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, and the presence of speed control. Only items applicable to vehicle hardware and supported by the VID block are displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. On selected vehicles equipped with permanent DTC reporting capabilities, neutral profile correction should be learned after a PCM replacement in order to activate the misfire monitor. This can be accomplished using the Misfire Monitor Neutral Profile Learn function on the scan tool. Reprogramming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the manufacturer's user manual for details. Programming the VID Block for a Replacement PCM The VID block on a replacement PCM is blank and requires programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it is replaced. Manual data entry must be carried out if the old module is damaged and is incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the Module/Parameter programming, referring to the manufacturer's user manual. Make certain that all parameters are included. Failure to correctly program tire size in revolutions per mile, (rev/mile = 63,360 divided by the tire circumference in inches) or axle ratio, may result in codes P1635 and P1639. You may be instructed to contact the As Built data center for the information needed to manually update the VID block with the scan tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury technicians, contact the National Hotline or Professional Technician Society (PTS) website for As Built data. Non-Ford technicians, use the Motorcraft website at Motorcraft.com. From the Motorcraft homepage, use the search function to find the Module Programming or As Built Data. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the scan tool. PCM Reprogramming Note: After the PCM is successfully reprogrammed, clear any TCM DTCs that may have been stored during reprogramming. At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 372 Engine Control Module: Removal and Replacement Powertrain Control Module (PCM) Removal 1. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation (PMI) procedure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 2. Detach the wiring harness retainer from the cowl stud bolt. 3. Disconnect the 3 PCM electrical connectors. 4. Remove the 2 bolts and the PCM. 5. Remove and inspect the PCM cowl seal. Install new if damaged. Installation 1. Install the PCM cowl seal. 2. Install the PCM and the 2 bolts. - Tighten to 8 Nm (71 lb-in). 3. Connect the 3 PCM electrical connectors. 4. Attach the wiring harness retainer to the cowl stud bolt. 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation (PMI) procedure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 > Locations > Page 380 Fuel Pump Control Unit: Service and Repair Fuel Pump Control Module Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Fuel Pump (FP) control module electrical connector. 3. NOTICE: Do not overtighten the fasteners or damage will occur. Remove the 2 bolts and the FP control module. - To install, tighten to 5 Nm (44 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 388 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 389 Air Bag Control Module: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 390 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 391 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 392 Air Bag Control Module: Service and Repair Restraints Control Module (RCM) Removal WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTICE: When installing a new Restraints Control Module (RCM), it is necessary to carry out Programmable Module Installation (PMI). Failure to follow these instructions may result in component damage and/or system failure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: Carrying out Programmable Module Installation (PMI) will not enable the 911 assist option that is disabled. The RCM and Accessory Protocol Interface Module (APIM) must be configured correctly to fully support 911 assist functionality. 1. If installing a new RCM, carry out the steps necessary to prepare for PMI. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 393 2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 3. Remove 2 front LH floor console screws and position the carpet to access the RCM bolts. 4. Remove the RCM access cover. - Remove the scrivet. - Pull forward to release the 2 retainer hooks and remove the RCM access cover. 5. Disengage the lock tab, press and disconnect the small RCM electrical connector. 6. Disconnect the large RCM electrical connector. 1. Pinch the thumb tab and pivot the connector position assurance lever all the way back until it stops. 2. Pull out and disconnect the RCM electrical connector. 7. Remove the 3 bolts and RCM. Installation 1. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. Install the RCM and 3 bolts. Tighten to 11 Nm (97 lb-in). 2. Make sure the connector position assurance lever is in the full release position before attempting to connect the connector. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 394 3. NOTICE: Putting the large Restraints Control Module (RCM) electrical connector into the RCM on an angle can cause bad electrical connections and damage components. Position the large RCM electrical connector into the RCM. - NOTICE: Do not push the connector to the point where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the Restraints Control Module (RCM) before using the lever to fully seat the connector. Failure to follow these instructions may result in component damage and/or system failure. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and slight resistance is felt. 4. Connect the RCM electrical connector. - Pivot the connector position assurance lever toward the RCM, drawing the connector in to the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 5. Connect the small RCM electrical connector and push the lock tab in. 6. Install the RCM access cover. - Attach the 2 retainer hooks to the instrument panel brace. - Install the scrivet. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 395 7. Position the carpet into place and install the 2 front LH floor console screws. 8. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 9. When installing a new RCM, carry out the steps necessary to complete Programmable Module Installation (PMI). 10. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn OFF. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 399 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Locations > Page 405 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Locations > Page 406 Steering Control Module: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Locations > Page 407 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 415 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 416 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 417 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 418 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 419 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 420 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 421 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 422 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 423 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 424 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 425 Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 426 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 427 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 428 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 429 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 430 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 431 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 432 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 433 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 434 Control Module: Connector Views Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 435 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 436 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 437 Control Module: Electrical Diagrams Transaxle Control Module (TCM) 29-1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 438 29-2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Page 439 Control Module: Testing and Inspection Transaxle Control Module (TCM) Reprogramming WARNING: THIS VEHICLE IS EQUIPPED WITH HIGH VOLTAGE CABLES, COMPONENTS, AND WIRING. THE HIGH VOLTAGE WARNING LABELS CONTAINING THE HIGH VOLTAGE SYMBOL ARE LOCATED ON EACH HIGH VOLTAGE COMPONENT. HIGH VOLTAGE CABLES AND WIRING ARE ORANGE IN COLOR. CERTIFIED RUBBER INSULATING GLOVES AND A FACE SHIELD MUST BE WORN WHEN WORKING WITH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING. THE IGNITION KEY MUST BE CYCLED TO THE OFF POSITION FOR A MINIMUM OF 5 MINUTES, AND THE HIGH VOLTAGE TRACTION BATTERY SERVICE DISCONNECT PLUG PLACED IN THE SERVICING/SHIPPING POSITION BEFORE DISCONNECTING THE HIGH VOLTAGE CABLES. DO NOT DISCONNECT, DISABLE, OR TOUCH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING DURING THE MODULE REPROGRAMMING PROCEDURE BECAUSE HIGH VOLTAGE IS PRESENT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH. Description Note: After the TCM is successfully reprogrammed clear the continuous diagnostic trouble codes (DTCs) in the powertrain control module (PCM) and the TCM that may have been stored during reprogramming. Changes made to the strategy or calibration may require TCM reprogramming. Refer to the Module Programming instructions on the scan tool. Making Changes To The TCM Calibration If the TCM does not complete the reflash after two consecutive attempts, follow the instructions listed below: 1. If the TCM reprogramming aborts during the procedure: - Reprogram the TCM again. - After the TCM reprogramming is successfully completed, clear the continuous DTCs in the PCM and the TCM. 2. If the TCM reprogramming aborts immediately after the start: - Turn the key OFF. - Disconnect the PCM body/cowl connector, and leave it disconnected. - Turn the key ON. - Start the TCM reprogramming. - After the TCM reprogramming is successfully completed, turn the key OFF and connect the PCM body/cowl connector. - Clear any PCM and TCM DTCs that may have been stored during reprogramming. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 444 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 445 Control Module: Service and Repair 4X4 Control Module Removal and Installation 1. Remove the floor console. 2. Disconnect the electrical connector. 3. Lift upward on the module to release the fasteners from the shifter base. Remove the 4X4 control module. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 456 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 457 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 458 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 461 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 462 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 463 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 464 Parking Assist Distance Sensor: Service and Repair Parking Aid Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The rear bumper cover removal is only necessary for access to the outer parking aid sensors. The inner parking aid sensors do not require rear bumper cover removal for access. Remove the rear bumper cover. 3. Press the retaining tabs and remove the parking aid sensor(s). - Disconnect the electrical connectors. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations > Page 468 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations > Page 469 Parking Assist Switch: Service and Repair Parking Aid Switch Removal and Installation 1. Remove the lower instrument panel center finish panel. 2. Press the retaining tabs and remove the parking aid switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams > Page 473 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Brake Booster Travel Sensor - Hybrid Removal and Installation 1. Disconnect the brake booster travel sensor electrical connector. 2. Release the brake booster travel sensor retainer ring and remove the travel sensor. 3. To install, reverse the removal procedure. 4. Following the scan tool instructions, carry out the multi-calibration routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Console Lamp Switch > Component Information > Service and Repair Console Lamp Switch: Service and Repair Ambient Lighting Switch Removal and Installation 1. Remove the floor console finish panel. - Disconnect the electrical connector. 2. Squeeze the retaining tabs and remove the ambient lighting switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 482 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 485 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 486 Power Door Lock Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 487 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 488 Power Door Lock Switch: Service and Repair Door Lock Control Switch NOTE: LH side shown, RH side similar. Removal and Installation 1. Remove the front interior door handle. For additional information, refer to Interior Door Handle Front See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Handle/Front Door Interior Handle/Service and Repair/Interior Door Handle - Front. 2. Release the tabs and remove the door lock control switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 492 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 493 Power Mirror Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 494 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 495 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 496 Power Mirror Switch: Service and Repair Exterior Mirror Control Switch Removal and Installation 1. Remove the LH sail panel. - Disconnect the electrical connector. 2. Remove the exterior mirror control switch. - Press the 2 retaining tabs. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 500 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 501 Power Seat Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 502 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 503 Power Seat Switch: Service and Repair Seat - Exploded View, Front Seat Backrest - Front NOTE: Driver seat shown, passenger seat similar. Seat Cushion - Driver NOTE: Power seat track shown, manual seat track similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 504 Seat Cushion - Front, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 505 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Service and Repair > Liftgate Release Switch Power Trunk / Liftgate Lock Switch: Service and Repair Liftgate Release Switch Liftgate Release Switch Removal and Installation 1. Remove the liftgate trim panel. 2. Remove the 4 liftgate trim bezel nuts and remove the bezel from the liftgate. - To install, tighten to 8 Nm (71 lb-in). - Disconnect the electrical connector. - Using the appropriate tool, press the tabs and remove the liftgate release switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Service and Repair > Liftgate Release Switch > Page 511 Power Trunk / Liftgate Lock Switch: Service and Repair Liftgate Release Switch - Liftgate Window Liftgate Release Switch - Liftgate Window Removal and Installation 1. Remove the liftgate trim panel. 2. Remove the 4 liftgate trim bezel nuts and remove the bezel from the liftgate. - To install, tighten to 8 Nm (71 lb-in). - Disconnect the liftgate window release switch electrical connector. - Using the appropriate tool, press the tabs and remove the liftgate window release switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front Seat Heater Switch: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Seat Backrest - Front NOTE: Driver seat shown, passenger seat similar. Seat Cushion - Driver NOTE: Power seat track shown, manual seat track similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 516 Seat Cushion - Front, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 517 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 518 Seat Heater Switch: Service and Repair Seat Control Switch Seat Control Switch Removal and Installation NOTE: For component identification and locations, refer to Seat - Exploded View, Front See: Body and Frame/Seats/Service and Repair/Front Seats/Seat - Exploded View, Front. 1. Remove the recliner handle cover. 2. Remove the seat control switch knob. 3. Remove the outboard side shield. - Remove the 3 screws and detach the side shield. - Disconnect the seat control switch electrical connector. 4. Remove the knob and seat control switch. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Roof Opening Panel Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Roof Opening Panel Switch > Page 523 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 524 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 525 Sunroof / Moonroof Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 526 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations > Page 530 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Switch: > 10-5-1 > Mar > 10 > Body - Uncommanded Liftgate Opening Trunk / Liftgate Switch: Customer Interest Body - Uncommanded Liftgate Opening TSB 10-5-1 03/29/10 LIFTGATE OPENING UN-COMMANDED OR NOT OPENING WHEN COMMANDED WHEN PARKED - INTERMITTENT FORD: 2008-2009 Escape MERCURY: 2008-2009 Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles built on or before 8/31/2008 may exhibit the liftgate opening un-commanded, or not opening when commanded while vehicle is parked. This may be due to water intrusion into the switch connector causing corrosion at the liftgate rear switch. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Refer to Workshop Manual (WSM), Section 501-14 for additional diagnostics. 1. Remove the liftgate trim panel. Refer to WSM, Section 501-05. 2. Remove the four (4) liftgate trim bezel nuts and remove the bezel from the liftgate. 3. Closely inspect the liftgate release switch and harness connector pins for signs of water intrusion and/or corrosion. Is any evidence of water intrusion or corrosion present? (Figure 1) a. No - Do not continue with this procedure. Refer to WSM, Section 501-14 for additional diagnostics. b. Yes - Replace the liftgate release switch per WSM, Section 501-14, and install new Pigtail Wiring Kit per Wiring Diagram, Section 5-1. Parts Block 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Switch: > 10-5-1 > Mar > 10 > Body - Uncommanded Liftgate Opening > Page 539 100S01A 2008-2009 Escape, 0.6 Hr. Mariner: Replace The Liftgate Release Switch And The Wiring Pigtail (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 13412 12 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Switch: > 10-5-1 > Mar > 10 > Body - Uncommanded Liftgate Opening Trunk / Liftgate Switch: All Technical Service Bulletins Body - Uncommanded Liftgate Opening TSB 10-5-1 03/29/10 LIFTGATE OPENING UN-COMMANDED OR NOT OPENING WHEN COMMANDED WHEN PARKED - INTERMITTENT FORD: 2008-2009 Escape MERCURY: 2008-2009 Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles built on or before 8/31/2008 may exhibit the liftgate opening un-commanded, or not opening when commanded while vehicle is parked. This may be due to water intrusion into the switch connector causing corrosion at the liftgate rear switch. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Refer to Workshop Manual (WSM), Section 501-14 for additional diagnostics. 1. Remove the liftgate trim panel. Refer to WSM, Section 501-05. 2. Remove the four (4) liftgate trim bezel nuts and remove the bezel from the liftgate. 3. Closely inspect the liftgate release switch and harness connector pins for signs of water intrusion and/or corrosion. Is any evidence of water intrusion or corrosion present? (Figure 1) a. No - Do not continue with this procedure. Refer to WSM, Section 501-14 for additional diagnostics. b. Yes - Replace the liftgate release switch per WSM, Section 501-14, and install new Pigtail Wiring Kit per Wiring Diagram, Section 5-1. Parts Block 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Switch: > 10-5-1 > Mar > 10 > Body - Uncommanded Liftgate Opening > Page 545 100S01A 2008-2009 Escape, 0.6 Hr. Mariner: Replace The Liftgate Release Switch And The Wiring Pigtail (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 13412 12 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > Page 546 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > Page 547 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 555 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 556 Brake Booster Vacuum Sensor: Service and Repair Brake Booster Vacuum Sensor - Hybrid Removal and Installation 1. Disconnect the brake booster vacuum sensor electrical connector. 2. Release the brake booster vacuum sensor retainer ring and remove the vacuum sensor. 3. To install, reverse the removal procedure. 4. Following the scan tool instructions, carry out the multi-calibration routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 560 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 564 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 568 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 572 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 573 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Remove the parking brake release handle bolt. - To install, tighten to 10 Nm (89 lb-in). 2. Disconnect the warning indicator switch electrical connector. 3. Remove the bolt and warning indicator switch. - To install, tighten bolt to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 577 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 578 Traction Control Switch: Service and Repair Stability/Traction Control Switch Removal and Installation 1. Remove the lower Instrument Cluster (IC) center finish panel. 2. Depress the 2 tabs and remove the stability/traction control switch assembly. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams > Page 582 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Brake Booster Travel Sensor - Hybrid Removal and Installation 1. Disconnect the brake booster travel sensor electrical connector. 2. Release the brake booster travel sensor retainer ring and remove the travel sensor. 3. To install, reverse the removal procedure. 4. Following the scan tool instructions, carry out the multi-calibration routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel Wheel Speed Sensor: Customer Interest ABS/TCS - Clicking Noise From Left Front Wheel TSB 09-5-5 03/23/09 LEFT FRONT ABS SENSOR CONTACTING TONE RING - VEHICLES BUILT 10/21/2008-10/31/2008 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built from 10/21/2008 to 10/31/2008 may exhibit a clicking or rubbing noise from the left front wheel speed sensor and/or exhibit ABS warning light activation. The left front wheel knuckle may have been machined incorrectly allowing the wheel speed sensor to contact the tone ring. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Measure the air gap between the left front wheel speed sensor and tone ring with a feeler gage. 2. If 0.02" (0.50 mm) or more - this procedure does not apply. Continue with normal diagnostics. 3. If less than 0.02" (0.5 mm) or evidence of contact - replace the left front wheel knuckle per Workshop Manual (WSM), Section 204-01 and the left front Wheel Speed Sensor per WSM, Section 206-09. Parts Block 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 090505A 2009 Escape Hybrid, 1.3 Hrs. Mariner Hybrid: Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Be Claimed With Operations B And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505A 2009 Escape, Mariner: 1.2 Hrs. Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel > Page 591 Be Claimed With Operations B And/Or C (Do Not Use With 2001 B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505B 2009 Escape, Mariner, 0.6 Hr. Escape Hybrid, Mariner Hybrid: Check Caster, Camber And Toe In Can Be Claimed With Operation A And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505C 2009 Escape, Mariner, 0.2 Hr. Escape Hybrid, Mariner Hybrid: Correct Toe-In Can Be Claimed With Operation A And B (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 3K186 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel Wheel Speed Sensor: All Technical Service Bulletins ABS/TCS - Clicking Noise From Left Front Wheel TSB 09-5-5 03/23/09 LEFT FRONT ABS SENSOR CONTACTING TONE RING - VEHICLES BUILT 10/21/2008-10/31/2008 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built from 10/21/2008 to 10/31/2008 may exhibit a clicking or rubbing noise from the left front wheel speed sensor and/or exhibit ABS warning light activation. The left front wheel knuckle may have been machined incorrectly allowing the wheel speed sensor to contact the tone ring. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Measure the air gap between the left front wheel speed sensor and tone ring with a feeler gage. 2. If 0.02" (0.50 mm) or more - this procedure does not apply. Continue with normal diagnostics. 3. If less than 0.02" (0.5 mm) or evidence of contact - replace the left front wheel knuckle per Workshop Manual (WSM), Section 204-01 and the left front Wheel Speed Sensor per WSM, Section 206-09. Parts Block 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 090505A 2009 Escape Hybrid, 1.3 Hrs. Mariner Hybrid: Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Be Claimed With Operations B And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505A 2009 Escape, Mariner: 1.2 Hrs. Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel > Page 597 Be Claimed With Operations B And/Or C (Do Not Use With 2001 B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505B 2009 Escape, Mariner, 0.6 Hr. Escape Hybrid, Mariner Hybrid: Check Caster, Camber And Toe In Can Be Claimed With Operation A And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505C 2009 Escape, Mariner, 0.2 Hr. Escape Hybrid, Mariner Hybrid: Correct Toe-In Can Be Claimed With Operation A And B (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 3K186 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 600 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 601 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 602 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 605 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 606 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 607 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front Wheel Speed Sensor - Front Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector is located in the engine compartment. Disconnect the electrical connector. 3. NOTICE: Care must be taken during the removal of the grommet to prevent damage. If the grommet is damaged, a new sensor may need to be installed, even though the sensor is functional in all other aspects. Remove the grommet from the body. - When removing the body grommet, rotate the grommet into a position which allows the use of a small screwdriver to release the tabs on the underside of the body grommet. These 2 tabs are located at right angles to the sensor wire. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 610 4. Remove the front wheel speed sensor harness from the retainer. 5. Remove the front wheel speed sensor harness-to-body bolt. - To install, tighten to 9 Nm (80 lb-in). 6. Remove the front wheel speed sensor harness-to-strut bracket bolt. - To install, tighten to 15 Nm (133 lb-in). 7. Remove the front wheel speed sensor bolt from the wheel knuckle. - To install, tighten to 9 Nm (80 lb-in). 8. NOTE: Clean off any foreign material that may have collected around the sensor before removal. Remove the front wheel speed sensor. 9. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 611 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTICE: Care must be taken during the removal of the grommet to prevent damage. If the grommet is damaged, a new sensor may need to be installed, even though the sensor is functional in all other aspects. Remove the grommet from the body. - When removing the body grommet, rotate the grommet into a position which allows the use of a small screwdriver to release the tabs on the underside of the grommet. These 2 tabs are located at right angles to the sensor wire. 3. Disconnect the rear wheel speed sensor electrical connector. 4. Remove the rear wheel speed sensor harness from the harness retainer. 5. Remove the 3 rear wheel speed sensor harness bolts. - To install, tighten to 9 Nm (80 lb-in). 6. NOTE: Clean off any debris that may have collected around the sensor before removal. Remove the rear wheel speed sensor bolt from the wheel knuckle. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 612 - To install, tighten to 9 Nm (80 lb-in). 7. Remove the rear wheel speed sensor. 8. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 613 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring - Front Wheel Speed Sensor Ring - Front Removal 1. Remove the front halfshaft. 2. Using a suitable driver, remove the ABS wheel speed sensor ring. Installation Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 614 1. Install the new ABS wheel speed sensor ring and the tools on the halfshaft as shown in the previous illustration. 2. Install the ABS wheel speed sensor ring to the dimension as shown. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 615 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring - Rear Wheel Speed Sensor Ring - Rear Removal and Installation Front Wheel Drive (FWD) vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the rear wheel hub nut. - To install, tighten to 290 Nm (214 lb-ft). 3. Remove the sensor ring from the wheel hub. 4. To install, reverse the removal procedure. All-Wheel Drive (AWD) vehicles 5. The rear wheel speed sensor ring is integral to the rear axle halfshaft and cannot be repaired separately. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 621 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 622 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which the resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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 varying the resistance of the passive sensor causes a variation in total current flow. The CHT sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor provides 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 then initiates 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 See: Powertrain Management/Computers and Control Systems/Description and Operation/Powertrain Control Software Fail-Safe Cooling Strategy. Cylinder Head Temperature (CHT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 623 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. Detach the Cylinder Head Temperature (CHT) sensor cover and position aside. 2. Disconnect the CHT sensor electrical connector. 3. Remove the CHT sensor. - To install, tighten to 12 Nm (106 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Hybrid Drive Coolant Temperature Sensor > Component Information > Description and Operation Hybrid Drive Coolant Temperature Sensor: Description and Operation Motor Electronics Coolant Temperature (MECT) Sensor The MECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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. A thermistor type sensor is considered a passive sensor. 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 MECT provides motor electronics cooling system temperature information to the PCM. The PCM uses this information for determining when to activate the cooling system fans and indicate over-temperature. Typical Thread Type Sensor Motor Electronics Coolant Temperature (MECT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 631 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch Cruise Control Switch: Service and Repair Speed Control Switch Speed Control Switch Escape and Mariner shown, Hybrid similar Removal and Installation 1. Remove the speed control switch by pulling the switch toward the rear of the vehicle. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch > Page 636 Cruise Control Switch: Service and Repair Speed Control Deactivator Switch Speed Control Deactivator Switch Removal and Installation 1. Disconnect the electrical connector. 2. Rotate the speed control deactivator switch counterclockwise one-quarter turn. 3. Remove the speed control deactivator switch. 4. NOTE: When installing the speed control deactivator switch, it is automatically self-adjusting to the correct position. Do not pull up or push down on the pedal during installation. Initial installation of the speed control deactivator switch allows for one adjustment. If additional adjustments are necessary, install a new switch. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams > Page 640 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Brake Booster Travel Sensor - Hybrid Removal and Installation 1. Disconnect the brake booster travel sensor electrical connector. 2. Release the brake booster travel sensor retainer ring and remove the travel sensor. 3. To install, reverse the removal procedure. 4. Following the scan tool instructions, carry out the multi-calibration routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 645 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the pin-type retainer, the 5 bolts and the RH splash shield. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the Engine Oil Pressure (EOP) switch electrical connector. 4. Remove the EOP switch. - To install, tighten to 15 Nm (133 lb-in). 5. To install, reverse the removal procedure. - Apply thread sealant with PTFE to the EOP switch threads. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 648 Oil Pressure Sender: Service and Repair Exploded View - Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 649 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 650 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 651 Oil Pressure Sender: Service and Repair Exploded View - Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 652 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 653 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 658 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 659 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection Climate Control System Component Tests Ambient Temperature Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 663 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 664 Blower Motor Switch: Service and Repair Blower Motor Speed Control Removal and Installation 1. Lower the glove compartment. 2. Disconnect the blower motor speed control electrical connector. 3. Remove the 2 blower motor speed control screws. - To install, tighten to 3 Nm (27 lb-in). 4. Remove the blower motor speed control. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 668 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 669 Cabin Temperature Sensor / Switch: Testing and Inspection Climate Control System Component Tests In-Vehicle Temperature Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature and Humidity Sensor Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature and Humidity Sensor In-Vehicle Temperature and Humidity Sensor NOTE: In-vehicle temperature and humidity sensor shown. In-vehicle temperature sensor similar. Removal and Installation 1. NOTICE: Only position the instrument cluster finish panel away from the instrument panel enough to detach the in-vehicle temperature sensor without stressing the attached components. If the instrument cluster finish panel is positioned too far away from the instrument panel, damage to the wire harness or instrument cluster finish panel could result. Detach the instrument cluster finish panel and position it away from the instrument panel to allow access to the in-vehicle temperature sensor. 2. Release the 2 clips and detach the in-vehicle temperature sensor or in-vehicle temperature and humidity sensor. 3. Disconnect the in-vehicle temperature sensor or in-vehicle temperature and humidity sensor electrical connector. 4. Detach the aspirator hose from the venturi at the heater core and evaporator core housing. 5. Detach the aspirator hose from the instrument panel. 6. Remove the in-vehicle temperature sensor or in-vehicle temperature and humidity sensor. 7. NOTE: The venturi must be aligned correctly with the heater core and evaporator core housing for installation. When installing the venturi, it must be pressed into the heater core and evaporator core housing until an audible click is heard to indicated that it is correctly attached. Remove the venturi (if needed). 8. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature and Humidity Sensor > Page 672 Cabin Temperature Sensor / Switch: Service and Repair Ambient Air Temperature Sensor Ambient Air Temperature Sensor Removal and Installation 1. Detach the ambient air temperature sensor electrical connector from the bumper. 2. Disconnect and remove the ambient air temperature sensor. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 679 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Air Conditioning Evaporator Temperature Sensor / Switch: Description and Operation Air Conditioning Air Conditioning Evaporator Discharge Air Temperature Sensor NOTE: A second (auxiliary) evaporator discharge air temperature sensor is used for the auxiliary evaporator core on hybrid vehicles. The evaporator discharge air temperature sensor contains a thermistor. The resistance of this thermistor varies by a specific amount based on the evaporator discharge air temperature. The HVAC module measures a voltage ratio between the reference voltage it supplies to the sensor and the sensor return voltage to determine this resistance and the associated discharge air temperature. The evaporator discharge air temperature sensor maintains evaporator core temperature and prevents icing of the evaporator core. It does this by signaling the HVAC module to switch off the A/C request signal to the instrument cluster on 2.5L or 3.0L (4V) vehicles, or signaling the PCM to cycle the A/C compressor off when the evaporator discharge air temperature sensor reading falls below acceptable levels. The A/C request or A/C compressor will be switched back on when the evaporator temperature rises above acceptable levels. On hybrid vehicles, the A/C compressor will continue to run and the passenger zone valve will be closed by the PCM if the evaporator discharge air temperature sensor is reading a temperature below acceptable levels, but the TBCM is requesting A/C operation for HVTB cooling. This allows continued refrigerant flow to the auxiliary evaporator core while allowing the front (main) evaporator core to warm to acceptable levels. The evaporator discharge air temperature sensor is located on the heater core and evaporator core housing behind the glove compartment. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Air Conditioning > Page 682 Evaporator Temperature Sensor / Switch: Description and Operation Engine Control Components Air Conditioning Evaporator Temperature (ACET) Sensor The ACET is connected to the dual automatic temperature control (DATC). Evaporator temperature is transmitted to the PCM from the DATC through the controller area network (CAN). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 683 Evaporator Temperature Sensor / Switch: Service and Repair Air Conditioning (A/C) Evaporator Discharge Air Temperature Sensor Removal and Installation 1. Lower the glove compartment. 2. Detach the instrument panel wire harness pin-type retainer and position the wire harness away from the evaporator discharge air temperature sensor. 3. Disconnect the A/C evaporator discharge air temperature sensor electrical connector. 4. Gently pry upward and remove the A/C evaporator discharge air temperature sensor. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Locations > Page 687 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation High Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) High Pressure Switch The A/C high pressure switch is used for additional A/C system pressure control. For refrigerant containment control, the normally closed high pressure contacts open at a predetermined A/C pressure. This results in the A/C turning off, preventing the A/C pressure from rising to a level that would open the A/C high pressure relief valve. For fan control, the normally open medium pressure contacts close at a predetermined A/C pressure. This grounds the ACPSW circuit input to the PCM. The PCM then turns on the high speed fan to help reduce the pressure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Description and Operation Low Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Low Pressure Switch The A/C low pressure switch is used for additional A/C system pressure control. This normally closed switch opens when the refrigerant pressure drops below 152 kPa (22 psi). This results in the A/C turning off, preventing the evaporator from freezing. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions Solar Sensor: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 700 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 701 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 702 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 703 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 704 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 705 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 706 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 707 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 708 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 709 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 710 Solar 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 711 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 712 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 713 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 714 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 715 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 716 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 717 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 718 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 719 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 720 Solar Sensor: Description and Operation SOLAR AMPLIFIER (SUNLOAD SENSOR) The solar amplifier (dual-channel sunload sensor), supplies information to the DATC module indicating LH side and RH side sunload. The sunload senor is capable of sensing the intensity and direction of the solar rediation entering the cabin of the car through the windshield for comfort of the driver and front passenger. The smart junction box processes this information to control the air conditioning system. For information on the location and service of the sunload sensor. See: Locations Diagrams By Number, Diagram set 55-004 Auto Climate Control System. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 721 Solar Sensor: Service and Repair REMOVAL 1. Remove the instrument panel upper finish panel. 2. Disconnect the connector. 3. Remove the A/C sunload sensor from the instrument panel upper finish panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Hybrid Battery Service Switch > Component Information > Locations Hybrid Battery Service Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Hybrid Battery Service Switch > Component Information > Locations > Page 726 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Hybrid Drive Coolant Temperature Sensor > Component Information > Description and Operation Hybrid Drive Coolant Temperature Sensor: Description and Operation Motor Electronics Coolant Temperature (MECT) Sensor The MECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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. A thermistor type sensor is considered a passive sensor. 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 MECT provides motor electronics cooling system temperature information to the PCM. The PCM uses this information for determining when to activate the cooling system fans and indicate over-temperature. Typical Thread Type Sensor Motor Electronics Coolant Temperature (MECT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair Instrument Panel Dimmer Switch Removal and Installation 1. Remove the Instrument Cluster (IC) finish panel. 2. NOTE: The instrument panel dimmer switch is removed by releasing the tabs and pulling from behind. Release the tabs and remove the instrument panel dimmer switch assembly. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 737 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 741 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Gauge Sender: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Fuel Tank Filler Pipe Assembly Fuel Tank and Fuel Pump (FP) module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 744 Fuel Tank Supports Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 745 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 746 Fuel Gauge Sender: Service and Repair Fuel Pump Module Fuel Pump Module Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the Fuel Pump (FP) module access cover. 4. NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material. Disconnect the FP module electrical connector. 5. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage. Disconnect the fuel tube-to-FP module quick connect coupling. 6. Disconnect the fuel tank filler pipe recirculation tube-to-FP module quick connect coupling. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 747 7. NOTE: For initial fuel draining, it is required to remove the fuel through the fuel tank filler pipe recirculation tube port on the FP module. Connect the Fuel Storage Tanker to the fuel tank filler pipe recirculation tube port on the FP module and remove approximately one-fourth of the fuel (from a completely full tank), lowering the fuel level below the FP module mounting flange. 8. NOTICE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP module when removing the lock ring. NOTE: When installing the FP module, install a new O-ring seal. Install the Fuel Tank Sender Unit Wrench and remove the FP module lock ring. 9. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm. NOTE: Some residual fuel may remain in the FP module. Carefully drain into a suitable container. Completely remove the FP module from the fuel tank. 10. NOTE: Inspect the surfaces of the FP module flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded. NOTE: To install, apply clean engine oil to the O-ring seal. Remove and discard the FP module O-ring seal. 11. NOTE: Make sure to install a new FP module O-ring seal and lock ring. To install, reverse the removal procedure. Make sure the alignment arrows on the FP module and the fuel tank meet before tightening the FP module lock ring. - Tighten the FP lock ring until it meets the stop tabs on the fuel tank. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 751 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 752 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Remove the parking brake release handle bolt. - To install, tighten to 10 Nm (89 lb-in). 2. Disconnect the warning indicator switch electrical connector. 3. Remove the bolt and warning indicator switch. - To install, tighten bolt to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 757 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 758 Ambient Light Sensor: Service and Repair Light Sensor Removal and Installation 1. Remove the sensor from the instrument panel. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 762 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 763 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 764 Backup Lamp Switch: Service and Repair Reversing Lamp Switch Removal and Installation 1. Disconnect the reversing lamp switch electrical connector. 2. Remove the reversing lamp switch. - To install, tighten to 24 Nm (18 lb-ft). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 09-15-1 > Aug > 09 > ABS/TCS - Traction Control Lamp ON/DTC C1440 Set Brake Light Switch: Customer Interest ABS/TCS - Traction Control Lamp ON/DTC C1440 Set TSB 09-15-1 08/10/09 TRACTION CONTROL LIGHT WITH DTC C1440 - BUILT 6/1/2009-6/10/2009 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built on or between 6/1/2009 to 6/10/2009, may exhibit the traction control light on with DTC code C1440. If the vehicle is operated for an extended period following the illumination of the traction control light, a slight brake drag condition may be observed. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE If the vehicle was built on or between 6/01/2009 to 6/10/2009, and both the traction control light and DTC C1440 are present, then replace the brake pedal switch. If only one is present, and not the other, then proceed with normal diagnostics. Refer to Workshop Manual (WSM), Section 417-01 for brake pedal switch replacement. NOTE DO NOT PRESS OR PULL ON BRAKE PEDAL WHEN INSTALLING OR REMOVING THE STOPLAMP SWITCH OTHERWISE MISADJUSTMENT OR DAMAGE TO THE STOPLAMP SWITCH CAN OCCUR. Parts Block 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 091501A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Replace The Stoplamp Switch. Includes Time To Check For DTCs (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 13480 12 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09-15-1 > Aug > 09 > ABS/TCS - Traction Control Lamp ON/DTC C1440 Set Brake Light Switch: All Technical Service Bulletins ABS/TCS - Traction Control Lamp ON/DTC C1440 Set TSB 09-15-1 08/10/09 TRACTION CONTROL LIGHT WITH DTC C1440 - BUILT 6/1/2009-6/10/2009 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built on or between 6/1/2009 to 6/10/2009, may exhibit the traction control light on with DTC code C1440. If the vehicle is operated for an extended period following the illumination of the traction control light, a slight brake drag condition may be observed. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE If the vehicle was built on or between 6/01/2009 to 6/10/2009, and both the traction control light and DTC C1440 are present, then replace the brake pedal switch. If only one is present, and not the other, then proceed with normal diagnostics. Refer to Workshop Manual (WSM), Section 417-01 for brake pedal switch replacement. NOTE DO NOT PRESS OR PULL ON BRAKE PEDAL WHEN INSTALLING OR REMOVING THE STOPLAMP SWITCH OTHERWISE MISADJUSTMENT OR DAMAGE TO THE STOPLAMP SWITCH CAN OCCUR. Parts Block 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 091501A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Replace The Stoplamp Switch. Includes Time To Check For DTCs (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 13480 12 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 778 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 779 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 780 Brake Light Switch: Service and Repair Stoplamp Switch Removal and Installation NOTICE: Do not press or pull on brake pedal when installing or removing the stoplamp switch otherwise misadjustment or damage to the stoplamp switch could occur. 1. Disconnect the stoplamp switch electrical connector. 2. Rotate the stoplamp switch clockwise approximately one-eighth turn and remove the stoplamp switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Console Lamp Switch > Component Information > Service and Repair Console Lamp Switch: Service and Repair Ambient Lighting Switch Removal and Installation 1. Remove the floor console finish panel. - Disconnect the electrical connector. 2. Squeeze the retaining tabs and remove the ambient lighting switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 787 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 791 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 794 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 795 Headlamp Dimmer Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 796 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 797 Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation 1. Remove the steering column opening trim. 2. Remove the 3 lower steering column shroud screws. 3. Remove the upper and lower steering column shrouds. 4. Remove the 2 multifunction switch screws. 5. Disconnect the multifunction switch electrical connector and remove the switch. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 801 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 802 Headlamp Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 803 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 804 Headlamp Switch: Service and Repair Headlamp Switch Removal and Installation 1. Remove the instrument panel side finish panel. 2. NOTE: The headlamp switch is removed by pushing from behind. Release the tabs and remove the headlamp switch. - Disconnect the electrical connectors. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations > Page 808 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 812 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 813 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 814 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation 1. Remove the steering column opening trim. 2. Remove the 3 lower steering column shroud screws. 3. Remove the upper and lower steering column shrouds. 4. Remove the 2 multifunction switch screws. 5. Disconnect the multifunction switch electrical connector and remove the switch. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 820 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 821 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the powertrain control module (PCM) receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Powertrain Management/Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Accelerator Pedal Position (APP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 825 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 826 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. 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 volume of air 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. The MAF sensor is located between the air cleaner and the throttle body inside the air cleaner assembly. Mass Air Flow (MAF) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 827 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 screws and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 831 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 832 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The CMP sensor is a Hall-effect sensor that detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. The PCM also uses the CMP signal to select the correct ignition coil to fire. Typical Hall-effect CMP Sensor Camshaft Position (CMP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 833 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 3. NOTE: Lubricate the CMP sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 837 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 838 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates the 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. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between pulse wheel teeth. Typical Crankshaft Position (CKP) Sensor Crankshaft Position (CKP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 839 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts, the pin-type retainer (not shown) and the RH splash shield. 3. Turn the crankshaft clockwise until the hole in the crankshaft pulley is in the 3 o'clock position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 840 4. Remove the engine plug bolt. 5. NOTE: When the crankshaft contacts the Crankshaft TDC Timing Peg, the No. 1 cylinder will be at Top Dead Center (TDC). Install the Crankshaft TDC Timing Peg and turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg. 6. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 7. Remove the bolts and the CKP sensor. Installation 1. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6 mm x 18 mm bolt in the crankshaft pulley and thread it into the front cover. 2. Install the CKP sensor and the 2 bolts. - Do not tighten the bolts at this time. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 841 3. Adjust the CKP sensor with the Crankshaft Sensor Aligner. - Tighten the 2 CKP bolts to 7 Nm (62 lb-in). 4. Connect the CKP sensor electrical connector. 5. Remove the 6 mm x 18 mm bolt from the crankshaft pulley. 6. Install the engine plug bolt. - Tighten to 20 Nm (177 lb-in). 7. Install the RH splash shield, 5 bolts and the pin-type retainer (not shown). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 845 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 846 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which the resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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 varying the resistance of the passive sensor causes a variation in total current flow. The CHT sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor provides 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 then initiates 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 See: Powertrain Management/Computers and Control Systems/Description and Operation/Powertrain Control Software Fail-Safe Cooling Strategy. Cylinder Head Temperature (CHT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 847 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. Detach the Cylinder Head Temperature (CHT) sensor cover and position aside. 2. Disconnect the CHT sensor electrical connector. 3. Remove the CHT sensor. - To install, tighten to 12 Nm (106 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Level Sensor: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Fuel Tank Filler Pipe Assembly Fuel Tank and Fuel Pump (FP) module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 852 Fuel Tank Supports Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 853 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 854 Fuel Level Sensor: Service and Repair Fuel Pump Module Fuel Pump Module Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the Fuel Pump (FP) module access cover. 4. NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material. Disconnect the FP module electrical connector. 5. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage. Disconnect the fuel tube-to-FP module quick connect coupling. 6. Disconnect the fuel tank filler pipe recirculation tube-to-FP module quick connect coupling. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 855 7. NOTE: For initial fuel draining, it is required to remove the fuel through the fuel tank filler pipe recirculation tube port on the FP module. Connect the Fuel Storage Tanker to the fuel tank filler pipe recirculation tube port on the FP module and remove approximately one-fourth of the fuel (from a completely full tank), lowering the fuel level below the FP module mounting flange. 8. NOTICE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP module when removing the lock ring. NOTE: When installing the FP module, install a new O-ring seal. Install the Fuel Tank Sender Unit Wrench and remove the FP module lock ring. 9. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm. NOTE: Some residual fuel may remain in the FP module. Carefully drain into a suitable container. Completely remove the FP module from the fuel tank. 10. NOTE: Inspect the surfaces of the FP module flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded. NOTE: To install, apply clean engine oil to the O-ring seal. Remove and discard the FP module O-ring seal. 11. NOTE: Make sure to install a new FP module O-ring seal and lock ring. To install, reverse the removal procedure. Make sure the alignment arrows on the FP module and the fuel tank meet before tightening the FP module lock ring. - Tighten the FP lock ring until it meets the stop tabs on the fuel tank. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 856 Fuel Level Sensor: Service and Repair Fuel Level Sender Fuel Level Sender Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the Fuel Pump (FP) module. For additional information, refer to Fuel Pump Module See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Pump Module. 2. Disconnect the electrical connector, release the locking tabs and remove the fuel level sender from the FP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 857 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 861 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor The FTP sensor is used to measure the fuel tank pressure. In-line Fuel Tank Pressure (FTP) Sensor Fuel Tank Pressure (FTP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 865 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 866 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The IAT sensor is integrated into the mass air flow (MAF) sensor. It is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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. A thermistor type sensor is considered a passive sensor. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in the 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 sensor provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, and ignition timing. Integrated Intake Air Temperature (IAT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 870 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 871 Knock Sensor: Description and Operation Knock Sensor (KS) The KS 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 872 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the intake manifold. 3. Remove the bolt and the Knock Sensor (KS). - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 876 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 877 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor uses a piezo-resistive silicon sensing element to provide a voltage proportional to the absolute pressure in the intake manifold. The MAP sensor is part of the EGR system. The PCM uses information from the MAP, TP, MAF, CHT and CKP sensors to determine how much exhaust gas is introduced into the intake manifold. Typical Manifold Absolute Pressure (MAP) Sensor Manifold Absolute Pressure (MAP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 878 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the Throttle Body (TB). 3. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector. 4. Using a tool like KD Tool #58181 or Lisle T25 Torx Bit, remove the screw and the MAP sensor. - To install, tighten to 3 Nm (27 lb-in). 5. NOTE: Lubricate the MAP sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Oxygen Sensor: Customer Interest Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 887 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Oxygen Sensor: All Technical Service Bulletins Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 893 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 896 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #12 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #12 > Page 899 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 900 Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) The HO2S 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 voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a 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 a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Typical Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) Universal Heated Oxygen Sensor (HO2S) The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal HO2S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor Exploded View Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page 903 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S. - Calculate the correct torque wrench setting for the following torque. - To install, tighten to 48 Nm (35 lb-ft). 4. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page 904 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor Catalyst Monitor Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector. 3. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS. - Calculate the correct torque wrench setting for the following torque. - To install, tighten to 48 Nm (35 lb-ft). 4. NOTE: Apply a light coat of anti-seize lubricant to the threads of the CMS. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has two signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The two ETB throttle position sensor signals make sure the PCM receives a correct input even if one signal has a concern. There is one reference voltage circuit and one signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to the description of the Torque Based Electronic Throttle Control (ETC) See: Powertrain Management/Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. Electronic Throttle Body (ETB) Throttle Position Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 912 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 913 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the powertrain control module (PCM) receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Powertrain Management/Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Accelerator Pedal Position (APP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 917 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 918 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. 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 volume of air 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. The MAF sensor is located between the air cleaner and the throttle body inside the air cleaner assembly. Mass Air Flow (MAF) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 919 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 screws and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 926 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 927 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shut-off (IFS) Switch The IFS switch consists of a steel cone held in place by a magnet. When a sharp impact occurs, the cone breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner's Literature, Roadside Emergencies for the location of the IFS switch. Typical Inertia Fuel Shut-off (IFS) Switch Typical Inertia Fuel Shut-off (IFS) Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 928 Inertia Fuel Shutoff Switch: Service and Repair Inertia Fuel Shutoff (IFS) Switch 1. Remove the RH lower A-pillar trim panel. 2. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 3. Remove the 2 bolts and the IFS switch. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has two signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The two ETB throttle position sensor signals make sure the PCM receives a correct input even if one signal has a concern. There is one reference voltage circuit and one signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to the description of the Torque Based Electronic Throttle Control (ETC) See: Powertrain Management/Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. Electronic Throttle Body (ETB) Throttle Position Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 936 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 937 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The CMP sensor is a Hall-effect sensor that detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. The PCM also uses the CMP signal to select the correct ignition coil to fire. Typical Hall-effect CMP Sensor Camshaft Position (CMP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 938 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 3. NOTE: Lubricate the CMP sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 942 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 943 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates the 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. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between pulse wheel teeth. Typical Crankshaft Position (CKP) Sensor Crankshaft Position (CKP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 944 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts, the pin-type retainer (not shown) and the RH splash shield. 3. Turn the crankshaft clockwise until the hole in the crankshaft pulley is in the 3 o'clock position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 945 4. Remove the engine plug bolt. 5. NOTE: When the crankshaft contacts the Crankshaft TDC Timing Peg, the No. 1 cylinder will be at Top Dead Center (TDC). Install the Crankshaft TDC Timing Peg and turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg. 6. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 7. Remove the bolts and the CKP sensor. Installation 1. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6 mm x 18 mm bolt in the crankshaft pulley and thread it into the front cover. 2. Install the CKP sensor and the 2 bolts. - Do not tighten the bolts at this time. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 946 3. Adjust the CKP sensor with the Crankshaft Sensor Aligner. - Tighten the 2 CKP bolts to 7 Nm (62 lb-in). 4. Connect the CKP sensor electrical connector. 5. Remove the 6 mm x 18 mm bolt from the crankshaft pulley. 6. Install the engine plug bolt. - Tighten to 20 Nm (177 lb-in). 7. Install the RH splash shield, 5 bolts and the pin-type retainer (not shown). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Removal and Installation NOTE: For non-functional ignition lock cylinders, the steering column lock module has to be replaced. 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 954 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 955 Knock Sensor: Description and Operation Knock Sensor (KS) The KS 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 956 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the intake manifold. 3. Remove the bolt and the Knock Sensor (KS). - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 965 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 966 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 967 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 968 Impact Sensor: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 969 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 970 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 971 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 972 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 973 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 976 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 977 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 978 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 979 Impact Sensor: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 980 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 981 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor Impact Sensor: Service and Repair Front Impact Severity Sensor Front Impact Severity Sensor Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Disconnect the front impact severity sensor electrical connector. 3. NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. Remove the nut and front impact severity sensor. - To install, tighten to 11 Nm (97 lb-in). 4. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. To install, reverse the removal procedure. 5. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 984 Impact Sensor: Service and Repair Side Impact Sensor - First Row, B-Pillar Side Impact Sensor - First Row, B-Pillar NOTE: RH shown, LH similar. Removal WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the B-pillar trim panel. 3. Disconnect the electrical connector. 4. Remove the bolt and side impact sensor. - Tighten to 6 Nm (53 lb-in). 5. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. NOTE: Make sure the B-pillar and side impact severity sensor mating surfaces are clean and free of foreign material. To install, reverse the removal procedure. 6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 985 Impact Sensor: Service and Repair Side Impact Sensor - Second Row, C-Pillar Side Impact Sensor - Second Row, C-Pillar NOTE: LH shown, RH similar. Removal WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the C-pillar trim panel. 3. Disconnect the electrical connector. 4. Remove the bolt and side impact sensor. - Tighten to 6 Nm (53 lb-in). 5. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. NOTE: Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign material. To install, reverse the removal procedure. 6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 990 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 993 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Tension Sensor > Component Information > Description and Operation Seat Belt Tension Sensor: Description and Operation Safety Belt System WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. When replacing safety belt buckles and/or retractor assemblies, use only the replacement parts specified in the Ford Customer Service Division Master Parts and Accessories Catalog. Belt Tension Sensor (BTS) The BTS operates as part of the Occupant Classification Sensor (OCS) system on the front passenger seat. To diagnose the BTS, refer to Air Bag Systems. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 1000 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Original Equipment Occupant Classification Sensor - Original Equipment Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 1003 Removal NOTE: Occupant Classification Sensor (OCS) system components, seat cushion foam pad, bladder with pressure sensor and OCSM, are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and OCSM) must be installed as an assembly. NOTE: To identify between a production OCS system and a service OCS system (OCS service kit), inspect the electrical connector. A production OCS system allows the disconnect of the OCSM electrical connector. A service OCS system (OCS service kit) has the electrical connector glued to the OCSM. It cannot and should not be disconnected or altered. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the passenger seat and depower the SRS. 2. Disconnect the electrical connectors and detach the wiring clips. 1. Disconnect the Occupant Classification System Module (OCSM) electrical connector. 2. Disconnect the pressure sensor electrical connector. 3. Release the 2 wiring clips on the wiring harness from the seat cushion pan. 4. If equipped with heated seats, disconnect the heated seat relay electrical connector, release the wiring clip on the wiring harness from the seat cushion pan, and disconnect the 2 cushion heater mat electrical connectors. 3. Remove the 4 seat cushion bolts retaining the seat cushion to the seat track. 4. NOTICE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure. Remove the seat cushion and pan assembly. To aid in removal, recline the seat. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 1004 5. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad. Detach the seat cushion trim cover J-clips from the seat cushion pan and remove the seat cushion trim cover. 6. Remove the seat cushion foam pad. 7. Bend the retaining tab away from the pressure sensor, then slide the pressure sensor off the bracket. 8. NOTICE: Care must be taken to prevent damage to the seat cushion pan when removing the rivets. Remove the 2 rivets and the OCSM. 9. Remove the 2 pin-type retainers from the OCS bladder and seat cushion pan. 10. Feed the OCS hose and pressure sensor through the seat cushion pan opening and remove as an assembly with the bladder. Installation NOTICE: To prevent system failure, it is necessary to carry out the Occupant Classification Sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. NOTICE: Do not install a new cushion heater mat on a front passenger seat cushion, it is not serviceable separately. If a new cushion heater mat is needed on the front passenger seat, an Occupant Classification Sensor (OCS) system service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. 1. Bend the retaining tab back on the pressure sensor component bracket. 2. NOTICE: Inspect the Occupant Classification Sensor (OCS) bladder, seat cushion pan and support assembly for any foreign objects before installing the OCS to the seat cushion pan. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure. NOTICE: Route the seat Occupant Classification Sensor (OCS) components through the correct seat cushion support opening. Failure to follow these instructions may result in component damage and/or system failure. NOTICE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 1005 Feed the OCS components (pressure sensor and hose) through the seat cushion pan opening. 3. Align the OCS bladder to the seat cushion pan. 4. Install the 2 pin-type retainers to the OCS bladder and seat cushion pan. 5. NOTE: Make sure the pressure sensor hose is not kinked during installation. Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining tab is completely engaged. - When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab. 6. Slide the OCSM into the seat cushion pan bracket and install the rivets. - The OCSM must be correctly positioned and securely fastened in place. Failure to do so can set a DTC in the RCM. 7. Position the foam pad to the seat cushion pan. 8. NOTICE: Inspect the seat cushion pad and seat cushion trim cover for any foreign material, before installing the seat cushion trim cover to the seat cushion pad. If any foreign material is found, remove it. Failure to follow these instructions may result in incorrect operation of the Occupant Classification Sensor (OCS) system and may cause system failure. Install the seat cushion trim cover to the seat cushion foam pad and attach the J-clips. 9. NOTICE: Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion trim cover to the seat cushion pad. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect operation of the Occupant Classification Sensor (OCS) system and may cause system failure. Position the seat cushion and pan assembly to the seat track. - To aid in installation, recline the seat backrest. 10. Install the 4 seat track-to-cushion frame bolts. - Tighten to 25 Nm (18 lb-ft). 11. Connect the electrical connectors and wiring clips. 1. Connect the OCSM electrical connector. 2. Connect the pressure sensor electrical connector. 3. Install the 2 wiring clips on the wiring harness to the seat cushion pan. 4. If equipped with heated seats, connect the heated seat relay electrical connector, install the wiring clip on the wiring harness to the seat cushion pan, and connect the 2 cushion heater mat electrical connectors. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 1006 12. Install the front passenger seat and repower the SRS. Do not prove out the SRS at this time. 13. WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTICE: To prevent system failure, the following precautions must be taken before carrying out the Occupant Classification Sensor (OCS) system reset: Make sure the voltage to the Occupant Classification System Module (OCSM) is above 8 volts and less than 18 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. Carry out the Occupant Classification Sensor (OCS) system reset. 14. If the first system reset attempt was unsuccessful, carry out a thorough visual inspection of the following and repair any concerns found. - OCS system connector and wiring for damage - Pressure sensor hose for kinks and/or damage - Seat-related wiring harness and body wiring harness terminals and connectors for damage 15. NOTE: The ignition switch must be cycled after the OCS system reset. Carry out a second OCS system reset. If the second attempt is unsuccessful, install a new OCS system service kit. 16. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 1007 sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all RCM and OCSM DTCs using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 1008 Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Service Kit Occupant Classification Sensor - Service Kit Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 1009 Removal WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTE: Occupant Classification Sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and Occupant Classification System Module (OCSM)) must be installed as an assembly. NOTE: To identify between a production OCS system and a service OCS system service kit, inspect the OCSM electrical connector. A production OCS system allows the disconnect of the OCSM electrical connector. A service OCS system (OCS service kit) has the OCSM electrical connector glued to the OCSM. It cannot and should not be disconnected or altered. NOTE: The seat wiring harness will be reused. The OCS service kit connector connects to the seat wiring harness OCSM connector. The pressure sensor seat wiring harness connector will be left unplugged and secured by a tie strap. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the passenger seat and depower the SRS. 2. NOTE: The seat wiring harness will be reused. Disconnect the electrical connector(s) and wiring clips in the following sequence. 1. Disconnect the seat wire harness OCS electrical connector from the service part OCS electrical connector. 2. Release the 2 wiring clips on the wiring harness from the seat cushion pan. 3. If equipped with heated seats, disconnect the heated seat module electrical connector, release the wiring clip on the wiring harness from the seat cushion pan, and disconnect the 2 cushion heater mat electrical connectors. 3. Remove the 4 seat track-to-cushion frame bolts. 4. NOTICE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure. Remove the seat cushion and pan assembly. To aid in removal, recline the seat. 5. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad. Detach the seat cushion trim cover J-clips from the seat cushion pan and remove the seat cushion trim cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 1010 6. Bend the retaining tab away from the pressure sensor, then slide the pressure sensor off the bracket. 7. NOTICE: Care must be taken to prevent damage to the seat cushion pan when removing the rivets. Failure to follow these instructions may result in component damage and/or system failure. Remove the 2 rivets and detach the OCSM from the seat cushion pan. 8. Remove the OCS. - Pull all the OCS components (hose, pressure sensor, wire harness, OCSM and connectors) through the seat cushion pan opening. Installation NOTICE: To prevent system failure, it is necessary to carry out the Occupant Classification Sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. NOTICE: Do not install a new cushion heater mat on a front passenger seat cushion, it is not serviceable separately. If a new cushion heater mat is needed on the front passenger seat, an Occupant Classification Sensor (OCS) system service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. 1. Bend the retaining tab back on the pressure sensor component bracket. 2. NOTICE: Inspect the Occupant Classification Sensor (OCS) bladder, seat cushion pan and support assembly for any foreign objects Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 1011 before installing the OCS to the seat cushion pan. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure. NOTICE: Route the seat Occupant Classification Sensor (OCS) components through the correct seat cushion support opening. Failure to follow these instructions may result in component damage and/or system failure. NOTICE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Failure to follow these instructions may result in component damage and/or system failure. Feed the OCS service kit components (hose, pressure sensor, OCSM, wire harness and connectors) through the seat cushion pan opening. 3. NOTE: When installing an OCS service kit, the seat wire harness pressure sensor electrical connector is not used. NOTE: Make sure the pressure sensor hose is not kinked during installation. Install the OCS components to the seat cushion pan. 1. Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining tab is completely engaged. - When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab. 2. Slide the OCSM into the seat cushion pan bracket. - The OCSM must be correctly positioned and securely fastened in place. Failure to do so can set a DTC in the RCM. 3. Install the rivets. 4. Attach the seat cushion trim cover J-clips to the seat cushion pan. 5. NOTICE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Failure to follow these instructions may result in component damage and/or system failure. Position the seat cushion and pan assembly to the seat track. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 1012 - To aid in installation, recline the seat. 6. Install the 4 seat track-to-cushion frame bolts. - Tighten to 25 Nm (18 lb-ft). 7. NOTE: Do not tie-strap any wiring to the OCS bladder and pressure sensor hose. Connect the electrical connector(s) and wiring clips in the following sequence. 1. Connect the seat wire harness OCS electrical connector to the service part OCS electrical connector. 2. Install the 2 wiring clips on the wiring harness to the cushion pan. 3. If equipped with heated seats, connect the heated seat module electrical connector, install the wiring clip on the wiring harness to the cushion pan, and connect the 2 cushion heater mat electrical connectors. 4. Tie-strap the unused seat wire harness pressure sensor electrical connector safely aside. 5. Tie-strap all loose wire harnesses and electrical connectors safely aside. 8. Install the front passenger seat and repower the SRS. Do not prove out the SRS at this time. 9. WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTICE: To prevent system failure, the following precautions must be taken before carrying out the Occupant Classification Sensor (OCS) system reset: Make sure the voltage to the Occupant Classification System Module (OCSM) is above 8 volts and less than 18 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. Carry out the OCS system reset. 10. If the first system reset attempt was unsuccessful, carry out a thorough visual inspection of the following and repair any concerns found. - OCS system connector and wiring for damage - Pressure sensor hose for kinks and/or damage - Seat-related wiring harness and body wiring harness terminals and connectors for damage 11. NOTE: The ignition switch must be cycled after the OCS system reset. Carry out a second OCS system reset. If the second attempt is unsuccessful, install a new OCS system service kit. 12. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 1013 - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all RCM and OCSM DTCs using a scan tool. 13. NOTE: When installing a new OCS, a prepaid return postcard is provided with the new OCS. The serial number for the new part and the Vehicle Identification Number (VIN) must be recorded and sent to Ford Motor Company. Fill out the necessary information on the OCS traceability card and return it along with the complete inoperative OCS to Ford Motor Company. When returning the inoperative OCS, include the following: seat cushion foam pad, bladder, OCSM, pressure sensor (transducer), hose, electrical connectors and wire harness (service part OCS only). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 1017 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 1018 Seat Position Sensor: Service and Repair Seat Position Sensor NOTE: Manual seat shown, power seat similar. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the driver seat. 2. Disconnect the seat position sensor electrical connector. 3. Push the tab ends inward to release the seat position sensor locking clip. Slide the seat position sensor forward to release the 2 hooks from the bracket and remove the seat position sensor. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Removal and Installation NOTE: For non-functional ignition lock cylinders, the steering column lock module has to be replaced. 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1027 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1028 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Programming and Relearning. NOTE: The Tire Pressure Monitoring System (TPMS) Training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. NOTE: Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place at the valve stem. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall at the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall at the valve stem and press and release the test button to train the RF tire pressure sensor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1035 8. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1036 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" when a vehicle is stationary to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall at the tire valve stem. 3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. This feedback may not always be present, do not rely on it to reflect the most recent pressure data. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. If the sensor still does not respond, attempt to activate the same sensor again using the customer activation tool (if available). If the sensor still fails to train, attempt to train the sensor with the vehicle doors open. Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor. Activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Mode Switch, CVT > Component Information > Diagrams Transmission Mode Switch: Diagrams Electrical Connectors C2096 (Vehicle Harness Side) C2096 (Component Side) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations Transmission Position Switch/Sensor: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 1045 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 1046 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 1047 Transmission Position Switch/Sensor: Description and Operation Transmission Range (TR) Sensor Overview The TR sensor communicates the gear selector position the driver selects to the PCM. The PCM determines a gear mode based on the TR input and the vehicle speed signal. The PCM then broadcasts a gear mode message over the communication link. The TCM uses the gear mode message to engage the transaxle in the gear the driver selected. The other control modules use the gear mode message to control the rear lamps or a brake shift interlock solenoid. The TR sensor is mounted at the base of the gear selector assembly and the sensor shaft is moved by the selector. Transmission Range (TR) Sensor TR Sensor and PCM Interface The TR sensor is a linear potentiometer device that provides the PCM with a percentage of input voltage proportional to the rotational angle of the sensor shaft. The TR sensor consists of: - two independent (TR-A1 and TR-A2) signals - two 5 volt reference (TR-VREF1 and TR-VREF2) lines - two signal return (TR-RTN1 and TR-RTN2) lines The TR-A1 signal has a negative voltage slope, meaning the voltage decreases when the sensor angle increases. The typical TR voltage ranges from approximately 4.3 volts in the PARK position to approximately 0.6 volt in the LOW gear position. The TR-A2 signal has a positive voltage slope. Voltages increase as the sensor angle increases. The typical voltage for the TR-A2 is about 1 volt in the PARK position to about 4.4 volts in the LOW gear position. The TR-VREF circuits are bussed together internal to the TR sensor, and both TR-RTN circuits are bussed together in the TR sensor. One of the TR-VREF and one of the TR-RTN circuits are dedicated signals from the PCM. This design of redundant signals protects against an open circuit condition. Voltage Versus Angle and Gear Selected Chart If the PCM detects a concern in one of TR signal inputs, it uses the other TR signal to determine what gear the driver selects. If the PCM detects one or more TR signals that are invalid, the PCM: - allows the vehicle to travel in DRIVE position or LOW gear position if the vehicle was driving forward at a significant speed when the concern was detected. - allows the vehicle to travel in REVERSE gear if the vehicle was driving backwards at a significant speed when the concern was detected. - broadcasts gear mode - NEUTRAL over the communication link when vehicle speed decreases to 8 km/h (5 mph). - sets the DTC and illuminates the indicator. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Control Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Control Switch > Page 1053 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Control Switch > Page 1054 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Control Switch > Page 1055 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Control Switch Power Window Switch: Diagrams Master Window Control Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Control Switch > Page 1058 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Control Switch > Page 1059 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Control Switch > Page 1060 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Control Switch > Page 1061 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 1064 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 1065 Power Window Switch: Testing and Inspection Window Control Switch, Passenger Side Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 1066 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 1067 Power Window Switch: Testing and Inspection Window Control Switch, Left Rear Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 1068 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 1069 Power Window Switch: Service and Repair Window Control Switch Removal and Installation NOTE: LH front window control switch shown, all others similar. 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 window control switch bezel from the door trim panel. 3. Release the locking tabs and remove the window control switch from the bezel. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1074 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1075 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1076 Windshield Washer Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1077 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1078 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation 1. Remove the steering column opening trim. 2. Remove the 3 lower steering column shroud screws. 3. Remove the upper and lower steering column shrouds. 4. Remove the 2 multifunction switch screws. 5. Disconnect the multifunction switch electrical connector and remove the switch. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1082 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1083 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1084 Wiper Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1085 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1086 Wiper Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation 1. Remove the steering column opening trim. 2. Remove the 3 lower steering column shroud screws. 3. Remove the upper and lower steering column shrouds. 4. Remove the 2 multifunction switch screws. 5. Disconnect the multifunction switch electrical connector and remove the switch. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Ball Joint Deflection, Ride Height, Side-to-Side Lean, Tire Balance Weight, and Tire Inflation Alignment: Specifications Ball Joint Deflection, Ride Height, Side-to-Side Lean, Tire Balance Weight, and Tire Inflation Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Ball Joint Deflection, Ride Height, Side-to-Side Lean, Tire Balance Weight, and Tire Inflation > Page 1092 Alignment: Specifications Material Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Ball Joint Deflection, Ride Height, Side-to-Side Lean, Tire Balance Weight, and Tire Inflation > Page 1093 Alignment: Specifications Alignment Specifications Alignment Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Ball Joint Deflection, Ride Height, Side-to-Side Lean, Tire Balance Weight, and Tire Inflation > Page 1094 Alignment: Specifications Torque Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Alignment: Description and Operation Camber Wheel Alignment Angles Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1097 Alignment: Description and Operation Caster Wheel Alignment Angles Caster Caster is the deviation from vertical of an imaginary line drawn through the pivot points (top of strut and lower ball joint), when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. The caster setting is not adjustable. A backward tilt is positive (+) and a forward tilt is negative (-). Front caster adjustment is not a separate procedure on this vehicle. The vehicle will tend to drift/pull toward the side with the lowest caster. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1098 Alignment: Description and Operation Incorrect Thrust Angle (Dogtracking) Wheel Alignment Angles Incorrect Thrust Angle (Dogtracking) Incorrect thrust angle (also known as dogtracking) is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1099 Alignment: Description and Operation Drift/Pull Wheel Alignment Angles Drift/Pull Pull is a tugging sensation felt by the hands on the steering wheel that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with the hands off the steering wheel. - A vehicle-related drift/pull on a flat road causes a consistent deviation from the straight-ahead path and requires constant steering input in the opposite direction to counteract the effect. - Drift/pull may be induced by conditions external to the vehicle (for example, wind or road crown). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1100 Alignment: Description and Operation Camber Wheel Alignment Angles Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Wheel Alignment Angles Caster Caster is the deviation from vertical of an imaginary line drawn through the pivot points (top of strut and lower ball joint), when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. The caster setting is not adjustable. A backward tilt is positive (+) and a forward tilt is negative (-). Front caster adjustment is not a separate procedure on this vehicle. The vehicle will tend to drift/pull toward the side with the lowest caster. Incorrect Thrust Angle (Dogtracking) Wheel Alignment Angles Incorrect Thrust Angle (Dogtracking) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1101 Incorrect thrust angle (also known as dogtracking) is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Drift/Pull Wheel Alignment Angles Drift/Pull Pull is a tugging sensation felt by the hands on the steering wheel that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with the hands off the steering wheel. - A vehicle-related drift/pull on a flat road causes a consistent deviation from the straight-ahead path and requires constant steering input in the opposite direction to counteract the effect. - Drift/pull may be induced by conditions external to the vehicle (for example, wind or road crown). Nibble Wheel Alignment Angles Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and experienced by the driver as small rotational oscillations of the steering wheel. Poor Groove Feel Wheel Alignment Angles Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Effort may be said to be "flat on-center." - Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of the gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. - In the diagnosis of a driveability problem, it is important to understand the difference between wander and poor groove feel. Poor Returnability/Sticky Steering Wheel Alignment Angles Poor Returnability/Sticky Steering Poor returnability and sticky steering are used to describe the poor return of the steering wheel to center after a turn or steering correction. Shimmy Wheel Alignment Angles Shimmy Shimmy, as experienced by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Toe Wheel Alignment Angles Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1102 Toe Positive Toe (Toe In) Negative Toe (Toe Out) The vehicle toe setting affects tire wear and directional stability. Wander Wheel Alignment Angles Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Front Camber and Caster Adjustment 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 4 front strut upper mounting bracket nuts. 3. Push the front strut mounting bracket downward and turn it to the desired position to set the camber and caster. Both camber and caster for the front suspension are adjustable. For additional information, refer to Steps 4 and 5. 4. NOTE: Notice the position of the strut rod in each position. NOTE: Arrows shown in illustrations are pointing towards the front of the vehicle. Use the following table for LH side camber and or caster adjustment. 5. NOTE: Notice the position of the strut rod in each position. NOTE: Arrows shown in illustrations are pointing towards the front of the vehicle. Use the following table for the RH side camber and or caster adjustment. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1105 6. Install the 4 front strut upper mounting bracket nuts. - Tighten to 40 Nm (30 lb-ft). 7. Recalibrate the steering wheel position sensor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1106 Alignment: Service and Repair Ride Height Measurement Ride Height Measurement Front Ride Height Measurement NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have a full tank of fuel. 1. Position a suitable surface gauge (such as Starrett 57D Surface Gauge), on a flat, level surface and adjust the gauge's arm until the scriber point is located in the center of the lower ball joint bolt. Lock the surface gauge in this position. 2. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement 2). 3. Position the surface gauge on the same flat, level surface as used in Step 1, adjust the gauge's arm until the scriber point is located in the center of the forward lower arm bolt. Lock the surface gauge in this position. 4. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement 3). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1107 5. Subtract measurement 3 from measurement 2 to obtain the front ride height. - Refer to Specifications. Rear Ride Height Measurement NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have a full tank of fuel. 1. Measure the distance between the flat level surface and the center of the shock absorber lower bolt (measurement 2). 2. Measure the distance between the flat level surface and the center of the lower arm inner bolt (measurement 3). 3. Subtract measurement 2 from measurement 3 to obtain the rear ride height. - Refer to Specifications. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1108 Alignment: Service and Repair Toe Adjustment Toe Adjustment Front Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off. Hold the steering wheel in the straight-ahead position using a suitable holding device. 3. Check the toe settings following 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 steering gear bellows clamp(s). 5. Loosen the tie-rod end jam nut(s). - Clean and lubricate the nut(s) and front wheel spindle tie-rod threads. 6. Rotate the front wheel spindle tie rods to increase or decrease the front toe. 7. NOTICE: Hold the tie-rod end stationary with a wrench while tightening the nut, or damage to the boot can occur. NOTE: Do not disturb the toe settings while tightening the nut(s). Tighten the tie-rod end jam nut(s) to 40 Nm (30 lb-ft). 8. Install the steering gear bellows clamp(s). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1109 9. Check the toe settings. Follow the equipment manufacturer's instructions. 10. Calibrate the steering wheel position sensor. Rear Toe Adjustment 1. NOTICE: The cam nut and cam bolt area must be free of foreign material to make sure of correct clamping. NOTE: Clean the general area of the joint to prevent foreign material from entering the joint. Clean the area using only mild liquids. NOTE: Jounce the vehicle to make sure that the suspension is in its normal, at-rest position. Check the toe setting using suitable wheel alignment equipment. 2. NOTE: Do not remove the rear knuckle cam nut and wheel knuckle bolts. If removed, clean the serrations in the bushing sleeve with a wire brush and install a new wheel knuckle bolt and cam nut. Loosen the LH and RH rear wheel knuckle bolts. 3. Turn the LH and RH adjusting cams simultaneously until the toe is within specification. 4. Tighten the LH and RH rear wheel knuckle bolts. - Using a suitable tool, hold the adjustment cam nut stationary while tightening the rear wheel knuckle bolt. - Tighten to 150 Nm (111 lb-ft). 5. Calibrate the steering wheel position sensor. For additional information, refer to Steering Wheel Position Sensor Calibration in the Diagnosis and Testing of Steering. See: Steering and Suspension/Steering/Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure Key ON Engine OFF (KOEO)............................................................................................................... .........................................................379 kPa (55 psi) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1114 Fuel Pressure: Testing and Inspection Fuel System Pressure Test WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. NOTE: Early build 3.0L engines are equipped with a Schrader valve on the fuel rail. Late build 3.0L engines do not have a Schrader valve. All vehicles 1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. For additional information, refer to Battery. Vehicles with 2.5L engine 3. Disconnect the fuel tube-to-fuel rail quick connect coupling. For additional information, refer to Quick Connect Coupling See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Quick Connect Coupling. 4. Install the Fuel Pressure Test Kit between the fuel tube and the fuel rail. Vehicles with early build 3.0L engine 5. Remove the fuel rail Schrader valve cap. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1115 6. Install the Fuel Pressure Test Kit to the fuel rail Schrader valve. Vehicles with late build 3.0L engine 7. Disconnect the fuel jumper tube-to-fuel tube quick connect coupling. For additional information, refer to Quick Connect Coupling See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Quick Connect Coupling. 8. Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel tube. All vehicles 9. NOTE: The Fuel Pump (FP) fuse was removed previously to release the fuel system pressure and must be installed to test the fuel system pressure. Install the FP fuse. 10. Connect the battery ground cable. For additional information, refer to Battery. 11. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 12. NOTE: Upon completion of the fuel system pressure test, open the drain valve on the Fuel Pressure Test Kit and release fuel system pressure and drain any residual fuel into a suitable container prior to removing the tool. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Measured/PID Values Hot Idle ................................................................................................................................................ ............................................................. 1072 RPM Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Intake Air System Components - Exploded View Air Cleaner (ACL) Assembly and Outlet Pipe Air Cleaner (ACL) Intake Pipe Intake Air Resonator Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1123 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel System Pressure Release WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. NOTE: The Fuel Pump (FP) fuse is located in the Battery Junction Box (BJB), location 22. Remove the FP fuse. 2. Start the engine and allow it to idle until it stalls. 3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released. 4. Turn the ignition switch to the OFF position. 5. When the fuel system service is complete, install the FP fuse. 6. NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for leaks prior to starting the engine. Start the vehicle and check the fuel system for leaks. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Firing Order Firing Order: Specifications Firing Order Firing Order.......................................................................................................................................... .........................................................................1-3-4-2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Firing Order > Page 1132 Firing Order: Specifications Engine Cylinder Identification Engine Engine Cylinder Identification Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark plug gap..................................................................................................................................... ....................................1.08-1.18 mm (0.042-0.046 in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 1137 Spark Plug: Specifications Torque Specifications Spark plugs........................................................................................................................................... ........................................................12 Nm (106 lb-in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1138 Spark Plug: Application and ID Spark plug............................................................................................................................................ .............................................................AYSF-32-YPC Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1139 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. - Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. - Install a new spark plug. 2. Check for oil fouling. - Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. - Correct the oil leak concern. - Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. Install new spark plugs. 4. Inspect for normal burning. - Check for light tan or gray deposits on the firing tip. 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. Install a new spark plug. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1140 6. Inspect for overheating, identified by white or light gray spots and with a bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. - Install new spark plugs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View Spark Plug: Service and Repair Engine Ignition Components - Exploded View Engine Ignition Components - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 1143 Spark Plug: Service and Repair Spark Plugs Spark Plugs Removal and Installation 1. Remove the ignition coils. For additional information, refer to Ignition Coil-On-Plug See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil-On-Plug. 2. NOTICE: Only use hand tools when removing or installing the spark plugs, or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material in the spark plug well prior to removing the spark plugs. Remove the spark plugs. - To install, tighten to 12 Nm (106 lb-in). 3. Inspect the spark plugs. 4. To install, reverse the removal procedure. - Adjust the spark plug gap as necessary. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil meeting Ford specification on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are worn or damaged. 2. If compression does not improve, valves are sticking or not seating correctly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so the lowest reading is within 75% of the highest reading. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1147 Compression Check: Testing and Inspection Engine Component Tests The following component tests are used to diagnose engine concerns. Compression Test - Hybrid The compression test requires cranking the engine a minimum of 5 compression strokes with the throttle plate in the wide-open position for each cylinder. The engine cranking diagnostic mode must be used to crank the engine and the brake/accelerator pedals must be used to position the throttle plate during the compression test. The engine cranking diagnostic mode is a PCM strategy which is separate from the normal operating strategy. It allows the engine to crank in a similar fashion as a conventional vehicle with the fuel disabled. When in this mode, the PCM commands the Transmission Control Module (TCM) to spin the generator, which cranks the engine with the speed between 900 and 1,200 rpm. The engine will crank as long as the traction battery state of charge stays greater than 35%. 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level. Operate the vehicle until the engine is at normal operating temperature. 2. Using the Vehicle Communication Module (VCM), access the Battery Control Module (BCM) and monitor the traction battery state of charge PID. If the monitored PID displays the state of charge below 45%, start and idle the engine with full A/C ON. When the traction battery state of charge exceeds 45%, the engine cranking diagnostic mode can be activated. 3. Turn the ignition switch to the OFF position, then remove all the spark plugs. 4. Install a compression gauge in the No. 1 cylinder. 5. Activate the cranking diagnostic mode as follows: - Apply the parking brake. - Place the gear selector in the PARK position. - Verify the key is in the OFF position. - NOTE: Do not crank the engine. Turn the key to the ON position with the engine OFF. - Within 5 seconds of the key in the ON position, fully apply the accelerator pedal and hold for 10 seconds. - Within 5 seconds release the accelerator pedal, shift the gear selector to the NEUTRAL position and fully apply the accelerator pedal. - Hold the accelerator pedal fully applied for 10 seconds. - Release the accelerator pedal and shift the gear selector to the PARK position. If the sequence is correctly executed, the instrument cluster hazard indicator (red triangle) flashes once per second when the gear selector is shifted to the PARK position. The PCM exits the engine cranking diagnostic mode when the traction battery state of charge drops below 35%, the gear selector is shifted to any gear other than PARK or when the ignition key is turned to the OFF or ACC position. 6. NOTE: If the ignition key stays in the START position for 15 seconds or longer, the PCM may set DTC P2535. NOTE: If the brake pedal is not depressed and held prior to depressing the accelerator pedal, the throttle plate will fail to open. Crank the engine as follows: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1148 - Depress and hold the brake pedal. - Fully depress and hold the accelerator pedal. - Turn the key to the START position and crank the engine a minimum of 5 compression strokes and record the highest reading. Return the key to the ON position. - Release the accelerator pedal. - Release the brake pedal. 7. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 8. Position the key to the OFF position to deactivate the cranking diagnostic mode. 9. Clear all DTCs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications NOTE: The nominal clearance is: intake:............................................................................................. .........................................................................................................0.25 mm (0.0095 in). exhaust:..... .............................................................................................................................................................. .................................0.30 mm (0.0115 in). The acceptable clearances after being fully installed are: intake:........................................................ .............................................................................................................................0.22-0.28 mm (0.008-0.011 in). exhaust:..................................................................................................................... ..............................................................0.27-0.33 mm (0.010-0.013 in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1152 Valve Clearance: Adjustments Valve Clearance Check 1. Remove the valve cover. For additional information, refer to Valve Cover See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Valve Cover. 2. Remove the 5 bolts, the pin-type retainer (not shown) and the RH splash shield. - To install, tighten to 9 Nm (80 lb-in). 3. NOTE: Turn the engine clockwise only, and only use the crankshaft bolt. NOTE: Before removing the camshafts, measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure the clearance of each valve and record its location. 4. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: The nominal clearance is: intake: 0.25 mm (0.0095 in). - exhaust: 0.30 mm (0.0115 in). The acceptable clearances after being fully installed are: - intake: 0.22-0.28 mm (0.008-0.011 in). - exhaust: 0.27-0.33 mm (0.010-0.013 in). Select tappets using this formula: tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. Select the closest tappet size to the ideal tappet thickness available and mark the installation location. 5. If any tappets do not measure within specifications, install new tappets in these locations. For additional information, refer to Valve Train Components - Exploded View See: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Valve Train Components Exploded View and Valve Tappets See: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and Push Rods/Lifter / Lash Adjuster/Service and Repair/Removal and Replacement/Valve Tappets. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Accessory Drive Accessory Drive Belt Routing Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Noise/Flutter Drive Belt: Testing and Inspection Drive Belt - Noise/Flutter Accessory Drive Component Tests Drive Belt - Noise/Flutter NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulleys have any fluids or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may occur. Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged or incorrectly aligned grooved pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on an accessory pulley under certain conditions. A short intermittent squeal may occur during engine start up and shut down or during very rapid engine acceleration and decelerations, such as: - Wide Open Throttle (WOT) 1-2 and 2-3 shifts or 2-3 and 3-4 back-out shifts on automatic transmissions. - WOT 1-2 and 2-3 shifts and any combination of rapid downshifting on manual transmissions. These special short-term transient events are expected, and are due to the higher system inertias required to meet the electrical and cooling demands on today's vehicle systems. Constant or reoccurring drive belt squeal can occur: - if the A/C discharge pressure goes above specifications: the A/C system is overcharged. - the A/C condenser core airflow is blocked. - the A/C anti-slugging strategy executes after a long hot heat soak. - if the A/C off equalized pressure (the common discharged and suction pressure that occurs after several minutes) exceeds specifications. - if any of the accessories or idler pulley(s) are damaged or have a worn or damaged bearing. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. - if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has been exposed to fluid contamination during vehicle operation, such as leaks from the power steering system, A/C system or cooling system, clean all pulleys with soap and water, rinse with clean water and install a new accessory drive belt. If the drive belt has been exposed to fluids in a localized area during routine vehicle service, such as replacement of hoses or fluids, the drive belt and pulleys should be washed with soap and water immediately (prior to starting the engine), and rinsed with clean water. - if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal installation wear range window, install a new accessory drive belt. - NOTE: The accessory drive belt tensioner arm should rotate freely without binding. Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Noise/Flutter > Page 1158 Drive Belt: Testing and Inspection Drive Belt - Incorrect Installation Accessory Drive Component Tests Drive Belt - Incorrect Installation NOTICE: Incorrect accessory drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the pulleys. Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive belt. Incorrect Installation Correct Installation With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking condition exists, proceed with the following: - Visually check the accessory drive belt tensioner for damage and wear, especially the mounting pad surface and arm alignment. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. If the tensioner arm is worn, the arm will be out of alignment. Either of these conditions will result in chirp and squeal noises. - With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Install new components as necessary. - Check all accessories, mounting brackets and the accessory drive belt tensioner for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck the accessory drive belt tracking. - Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware to specification. Recheck the accessory drive belt tracking. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View Drive Belt: Service and Repair Front End Accessory Drive (FEAD) - Exploded View Front End Accessory Drive (FEAD) - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View > Page 1161 Drive Belt: Service and Repair Accessory Drive Belt Accessory Drive Belt Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the pin-type retainer, 5 bolts and the RH splash shield. - To install, tighten to 9 Nm (80 lb-in). 3. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Intake Air System Components - Exploded View Air Cleaner (ACL) Assembly and Outlet Pipe Air Cleaner (ACL) Intake Pipe Intake Air Resonator Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1167 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations AIR DISTRIBUTION NOTE: A cabin air filter is available as a dealer-installed accessory. The accessory cabin air filter will be located in the air inlet under the right hand side of the cowl panel grill, if installed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations > Page 1171 Cabin Air Filter: Service and Repair AIR DISTRIBUTION NOTE: A cabin air filter is available as a dealer-installed accessory. The accessory cabin air filter will be located in the air inlet under the right hand side of the cowl panel grill, if installed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel System Pressure Release WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. NOTE: The Fuel Pump (FP) fuse is located in the Battery Junction Box (BJB), location 22. Remove the FP fuse. 2. Start the engine and allow it to idle until it stalls. 3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released. 4. Turn the ignition switch to the OFF position. 5. When the fuel system service is complete, install the FP fuse. 6. NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for leaks prior to starting the engine. Start the vehicle and check the fuel system for leaks. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element Oil Filter: Service and Repair Oil Filter Element Oil Filter Element Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Loosen the oil filter drain plug. 3. Using a cup-style oil filter wrench, loosen the oil filter cover one turn. 4. Remove the oil filter drain plug and drain the engine oil from the oil filter and adapter. - Remove and discard the oil filter drain plug O-ring seal. 5. Remove the oil filter cover and oil filter element. - Discard the oil filter element. - Remove and discard the oil filter cover O-ring seal. Installation 1. Wipe clean the oil filter cover and mounting surface on the oil filter adapter. 2. NOTE: Lubricate the oil filter cover O-ring seal with clean engine oil. Install a new oil filter cover O-ring seal. 3. NOTICE: Do not overtighten the oil filter cover. Overtightening the oil filter cover may damage the cover or O-ring seal and result in a oil leak. Install a new oil filter element and the oil filter cover. - Using a cup-style oil wrench, tighten to 33 Nm (24 lb-ft). 4. NOTE: Lubricate the oil filter drain plug O-ring seal with clean engine oil. Install a new oil filter drain plug O-ring seal. 5. NOTICE: Do not overtighten the oil filter drain plug. Overtightening the oil filter drain plug may damage the drain plug, O-ring seal or cover and result in a oil leak. Install the oil filter drain plug. - Tighten to 10 Nm (89 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element > Page 1180 Oil Filter: Service and Repair Variable Camshaft Timing (VCT) System Oil Filter Variable Camshaft Timing (VCT) System Oil Filter Removal and Installation 1. Remove the Variable Camshaft Timing (VCT) solenoid. 2. Remove the plug and the VCT system oil filter from the intake camshaft thrust cap. - To install, tighten to 17 Nm (150 lb-in). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element > Page 1181 Oil Filter: Service and Repair Exploded View - Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element > Page 1182 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element > Page 1183 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element > Page 1184 Oil Filter: Service and Repair Exploded View - Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element > Page 1185 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element > Page 1186 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly Hose/Line HVAC: Service and Repair Compressor Manifold and Tube Assembly Compressor Manifold and Tube Assembly - Hybrid Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the DC/DC converter. For additional information, refer to Hybrid Drive Systems. 4. Remove the front bumper cover. 5. Remove the condenser inlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 15 Nm (133 lb-in). 6. Remove the A/C compressor manifold bolt and disconnect the compressor manifold and tube from the A/C compressor. - Discard the O-ring seals. - To install, tighten to 20 Nm (177 lb-in). 7. Remove the 2 evaporator outlet line fitting nuts. - Discard the O-ring seals and gasket seals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1192 - To install, tighten to 15 Nm (133 lb-in). 8. Remove the compressor manifold and tube assembly bracket nut. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the compressor manifold and tube assembly. 10. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 11. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1193 Hose/Line HVAC: Service and Repair Compressor To Condenser Discharge Line Compressor to Condenser Discharge Line - 2.5L Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the RH lower engine splash shield. 4. Remove the front bumper cover. 5. Remove the condenser inlet fitting nut and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1194 6. Remove the A/C compressor suction fitting nut and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 7. Remove the A/C compressor discharge fitting nut and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 8. Remove the compressor-to-condenser discharge line. 9. To install, reverse the removal procedure. - Install new gasket and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1195 Hose/Line HVAC: Service and Repair Condenser To Receiver Drier Line Condenser to Receiver Drier Line Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Recover the refrigerant. 2. Remove the DC/DC converter. For additional information, refer to Hybrid Drive Systems. 3. Remove the front bumper cover. 4. Remove the compressor manifold and tube bracket nut. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1196 - To install, tighten to 8 Nm (71 lb-in). 5. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring seal. 6. Remove the evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 7. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 8. Remove the receiver/drier inlet fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 9. Remove the condenser-to-receiver/drier line. 10. To install, reverse the removal procedure. - Install new gasket seal and O-ring seal. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 11. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1197 Hose/Line HVAC: Service and Repair Evaporator Inlet Line Evaporator Inlet Line - Hybrid Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Recover the refrigerant. 2. Remove the evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 3. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1198 - To install, tighten to 15 Nm (133 lb-in). 4. Disconnect the low-charge protection switch electrical connector. 5. Remove the Thermostatic Expansion Valve (TXV) fitting nut and disconnect the fitting. - Discard the gasket seals. - To install, tighten to 15 Nm (133 lb-in). 6. Remove the passenger zone valve nut. - To install, tighten to 7 Nm (62 lb-in). 7. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 8. Remove the receiver/drier outlet fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 9. Disconnect the passenger zone valve electrical connector. 10. Detach the evaporator inlet line from the A/C line bracket. 11. Remove the evaporator inlet line. 12. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 13. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1199 Hose/Line HVAC: Service and Repair Compressor Manifold and Tube Assembly Compressor Manifold and Tube Assembly - Hybrid Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the DC/DC converter. For additional information, refer to Hybrid Drive Systems. 4. Remove the front bumper cover. 5. Remove the condenser inlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 15 Nm (133 lb-in). 6. Remove the A/C compressor manifold bolt and disconnect the compressor manifold and tube from the A/C compressor. - Discard the O-ring seals. - To install, tighten to 20 Nm (177 lb-in). 7. Remove the 2 evaporator outlet line fitting nuts. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1200 - Discard the O-ring seals and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 8. Remove the compressor manifold and tube assembly bracket nut. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the compressor manifold and tube assembly. 10. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 11. Evacuate, leak test and charge the refrigerant system. Compressor To Condenser Discharge Line Compressor to Condenser Discharge Line - 2.5L Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the RH lower engine splash shield. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1201 4. Remove the front bumper cover. 5. Remove the condenser inlet fitting nut and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 6. Remove the A/C compressor suction fitting nut and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 7. Remove the A/C compressor discharge fitting nut and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 8. Remove the compressor-to-condenser discharge line. 9. To install, reverse the removal procedure. - Install new gasket and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Condenser To Receiver Drier Line Condenser to Receiver Drier Line Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1202 Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Recover the refrigerant. 2. Remove the DC/DC converter. For additional information, refer to Hybrid Drive Systems. 3. Remove the front bumper cover. 4. Remove the compressor manifold and tube bracket nut. - To install, tighten to 8 Nm (71 lb-in). 5. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring seal. 6. Remove the evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 7. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1203 - To install, tighten to 15 Nm (133 lb-in). 8. Remove the receiver/drier inlet fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 9. Remove the condenser-to-receiver/drier line. 10. To install, reverse the removal procedure. - Install new gasket seal and O-ring seal. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 11. Evacuate, leak test and charge the refrigerant system. Evaporator Inlet Line Evaporator Inlet Line - Hybrid Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1204 Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Recover the refrigerant. 2. Remove the evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 3. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 4. Disconnect the low-charge protection switch electrical connector. 5. Remove the Thermostatic Expansion Valve (TXV) fitting nut and disconnect the fitting. - Discard the gasket seals. - To install, tighten to 15 Nm (133 lb-in). 6. Remove the passenger zone valve nut. - To install, tighten to 7 Nm (62 lb-in). 7. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 8. Remove the receiver/drier outlet fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 9. Disconnect the passenger zone valve electrical connector. 10. Detach the evaporator inlet line from the A/C line bracket. 11. Remove the evaporator inlet line. 12. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 13. Evacuate, leak test and charge the refrigerant system. Auxiliary Evaporator Outlet and Inlet Line - Front Auxiliary Evaporator Outlet and Inlet Line - Front Front Connection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1205 Intermediate Connection NOTE: A/C service lines shown. Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1206 3. Remove the front auxiliary evaporator outlet line front fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 4. Remove the front auxiliary evaporator inlet line front fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 5. Disconnect the 2 front auxiliary evaporator outlet and inlet line mid-joint fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 6. Remove the front auxiliary evaporator outlet and inlet line bracket bolt. - To install, tighten to 6 Nm (53 lb-in). 7. Remove the auxiliary line dash panel bracket nut and detach the bracket. - To install, tighten to 6 Nm (53 lb-in). 8. NOTE: The auxiliary line bracket retainers are unscrewed for removal and pushed into place for installation. Remove the 2 auxiliary line bracket retainers and the front auxiliary evaporator outlet and inlet lines. 9. To install, reverse the removal procedure. - Install a new gasket seal and new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Auxiliary Evaporator Outlet and Inlet Line - Rear Auxiliary Evaporator Outlet and Inlet Line - Rear Rear Connection NOTE: A/C service lines shown. NOTE: This vehicle is not equipped with an in-line Thermostatic Expansion Valve (TXV) filter in the auxiliary evaporator inlet line fitting. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1207 Intermediate Connection NOTE: A/C service lines shown. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1208 Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. NOTE: The rear auxiliary evaporator outlet and inlet lines are installed from the factory as one-piece assemblies which must be cut for removal. Replacement lines must be installed if the lines are cut. The replacement parts are supplied as separate kits containing multiple piece lines for ease of installation. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the 2 rear auxiliary evaporator outlet and inlet line rear fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the rear auxiliary evaporator outlet and inlet line rear bracket bolt. - To install, tighten to 6 Nm (53 lb-in). 5. NOTE: If the vehicle is equipped with factory lines, it is necessary to cut the rear auxiliary evaporator outlet and inlet lines for removal. If equipped, disconnect the rear auxiliary evaporator outlet and inlet line tube-O fittings. - Discard the O-ring seals. - To install, tighten the 3/8-inch inlet line tube-O fitting to 10 Nm (89 lb-in). - To install, tighten the 5/8-inch outlet line tube-O fitting to 37 Nm (27 lb-ft). 6. Remove the 2 front auxiliary evaporator outlet and inlet line mid-joint fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the rear auxiliary evaporator outlet and inlet line front bracket bolt. - To install, tighten to 6 Nm (53 lb-in). 8. NOTE: The auxiliary line bracket retainers are unscrewed for removal and pushed into place for installation. Remove the 2 rear auxiliary line bracket retainers and remove the lines. 9. To install, reverse the removal procedure. - Install new O-ring seals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1209 - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Evaporator Outlet Line Evaporator Outlet Line - Hybrid Removal and Installation 1. Recover the refrigerant. 2. Disconnect the low-charge protection switch electrical connector. 3. Remove the evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 4. Remove the Thermostatic Expansion Valve (TXV) fitting nut and disconnect the fitting. - Discard the gasket seals. - To install, tighten to 15 Nm (133 lb-in). 5. Detach the evaporator outlet line from the A/C line bracket. 6. Remove the evaporator outlet line. 7. To install, reverse the removal procedure. - Install a new O-ring and new gasket seals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 1210 - Lubricate the refrigerant system with the correct amount of clean PAG oil. 8. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Ford P/N .............................................................................................................................................. .................................................................... PM-1-C Ford Specification ............................................. ......................................................................................................................................... WSS-M6C62-A Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine coolant ..................................................................................................................................... ............................................................. 7.4 qts (7.0L) Motor/Electronics (M/E) Coolant .......................................................................................................... ......................................................... 3.7 qts. (3.5 L) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1219 Coolant: Fluid Type Specifications Ford Part Name Motorcraft Premium Gold Engine Coolant with Bettering agent (yellow-colored) Ford Part Number ................................................................................................................................ ...................................................................... VC-7-B Ford Specification ................................................................................................................................ .................................................... WSS-M97B51-A1 Note: Add the coolant type originally equipped in your vehicle. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Vehicle Flat Towing Guidelines Fluid - A/T: Technical Service Bulletins A/T - Vehicle Flat Towing Guidelines TSB 09-20-13 10/19/09 6F35 TRANSMISSION - RECREATIONAL TOWING - VEHICLE WITH ALL 4 WHEELS ON THE GROUND - EXPANDED GUIDELINES TO PREVENT TRANSMISSION DAMAGE FORD: 2010 Fusion 2009-2010 Escape MERCURY: 2010 Milan 2009-2010 Mariner ISSUE Some 2009-2010 Escape, Mariner, 2010 Fusion and Milan vehicles equipped with a 6F35 automatic transmission, may experience transmission shift concerns after towing the vehicle with all 4 wheels on the ground (Flat tow) such as behind a motor home or a truck. The transmission shift concern may be caused by heat build up in the transmission due to the transmission fluid level being too high, towing speeds above 65 MPH (105 Km/h) and/or not stopping to run the engine at idle for 5 minutes every six hours or less, to cool the transmission. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE There are specific instructions listed in the Owner Guide that must be followed to recreational tow/flat tow/tow a vehicle with all 4 tires on the ground. Advise customers of the following expanded recreational towing guidelines. 1. Transmission fluid level must be checked at operating temperature of 185 °F - 200 °F (85 °C - 93 °C), per Workshop Manual (WSM), Section 307-01. At this temperature, adjust fluid level between minimum line and the minimum hole at the bottom of the hash marks on dipstick. This level is within the safe operating fluid level and does not require the customer to have the fluid level readjusted after flat tow operation. (Figure 1) 2. Maximum towing speed is 65 MPH (105 Km/h). 3. Do not flat tow the vehicle for greater than 6 hours at a time. 4. Start and run the engine for: a. 5 minutes before towing each day b. 5 minutes every 6 hours or less. c. While running the engine at idle for 5 minutes, with foot on the brake, shift through all gears. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Vehicle Flat Towing Guidelines > Page 1224 These guidelines are designed to prevent damage to the transmission due to overheating. If setting the fluid level for a customer that will be recreational (flat) towing the vehicle, set the level between minimum line and the minimum hole at the bottom of the hash marks on dipstick (Figure 1) per WSM Section 307-01. NOTE THERE IS A SIGNIFICANT DIFFERENCE IN TRANSMISSION DIPSTICK READINGS BETWEEN A COLD TRANSMISSION AND A TRANSMISSION AT OPERATING TEMPERATURE. FAILURE TO CHECK TRANS FLUID LEVEL AT TRANS OPERATING TEMPERATURE, PER WSM SECTION 307-01 MAY RESULT IN DAMAGE TO THE TRANSMISSION. If the vehicle is a 2009 Escape or Mariner and built on or before 10/28/2008 the dipstick does not have Minimum - Maximum lines outside of hash marks, then replace dipstick. 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 MT092013 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 7000 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Specifications > Capacity Specifications Fluid - CVT: Capacity Specifications Fluid Capacities Transmission Fluid............................................................................................................................... ....................................................4.05L (4.28 quarts)* Motor electronics cooling system......................................................................................................... ......................................................3.5L (3.7 quarts)** * Note: Transmission filled for life. The correct transaxle fill level is to the bottom of the fill plug, which is the upper plug. ** Note: Approximate dry fill capacity Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Specifications > Capacity Specifications > Page 1229 Fluid - CVT: Fluid Type Specifications Ford Part Name - Mercon LV Automatic Transmission Fluid Ford Part Number - XT-10-QLV Ford Specification - MERCON LV Note: Using any transmission fluid other than those that meet the recommended specification may cause internal transmission damage. Ford Part Name - Motorcraft Premium Gold Engine Coolant Ford Part Number - VC-7-B (US) - CVC-7-A (Canada) - Or equivalent Ford Specification - WSS-M97B51-A1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Rear Axle ............................................................................................................................................. .................................................. 2.96 pints (1.4 liters) NOTE: Fill to 1/4 inch to 9/16 inch (6 mm to 14 mm) below bottom of fill hole. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1234 Fluid - Differential: Fluid Type Specifications Differential Fluid Type REAR AXLE Motorcraft SAE 80W-90 Premium Rear Axle Lubricant Ford P/N .................................. .............................................................................................................................................................. ....... XY-80W90-QL Ford Specification ............................................................................................... ....................................................................................... WSP-M2C197-A NOTE: Vehicles exposed for prolonged periods to temperatures less than 40 Celsius (-40 Fahrenheit) should change out the rear axle fluid to Motorcraft SAE 75W-140 High Performance Rear Axle Lubricant, Ford part number XY-75W140-QL meeting Ford specification WSL-M2C192-A. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 09-4-4 > Mar > 09 > Drivetrain - Fluid leak From PTU Vent Fluid - Transfer Case: Customer Interest Drivetrain - Fluid leak From PTU Vent TSB 09-4-4 03/09/09 PTU VENT BOLT LEAK - MISDIAGNOSED AS PTU SHAFT SEAL LEAK FORD: 2005-2009 Escape Hybrid, Escape MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2005-2009 Escape, Mariner, Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit a leak from the power transfer unit (PTU) vent tube bolt. This may be misdiagnosed as a PTU link shaft seal leak. Please verify leak origin and tighten PTU vent tube bolt, before replacing parts. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the PTU fill plug and check fluid level per Workshop Manual (WSM), Section 308-07B. NOTE THE FLUID LEVEL MUST BE EVEN WITH THE BOTTOM OF THE FILLER HOLE WITH THE VEHICLE ON FLAT, LEVEL GROUND. 2. Inspect PTU vent tube bolt for leak. (Figure 1) a. If PTU vent tube bolt leaking - clean bolt contact sur[aces and torque bolt to 120 +/- 19 lb-in (13.5 +/- 2.1 N.m). b. If PTU vent tube bolt not leaking - continue with normal WSM, Section 308-07B diagnosis. NOTE THIS BOLT DOES NOT REQUIRE A WASHER FOR THIS APPLICATION. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 09-4-4 > Mar > 09 > Drivetrain - Fluid leak From PTU Vent > Page 1243 OPERATION DESCRIPTION TIME 090404A 2005-2009 Escape, 0.5 Hr. Mariner, Escape Hybrid, 2006-2009 Mariner Hybrid: Clean Bolt Contact Surfaces, Includes Time To Check And Adjust PTU Fluid Level DEALER CODING CONDITION BASIC PART NO. CODE 7034 24 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-4-4 > Mar > 09 > Drivetrain - Fluid leak From PTU Vent Fluid - Transfer Case: All Technical Service Bulletins Drivetrain - Fluid leak From PTU Vent TSB 09-4-4 03/09/09 PTU VENT BOLT LEAK - MISDIAGNOSED AS PTU SHAFT SEAL LEAK FORD: 2005-2009 Escape Hybrid, Escape MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2005-2009 Escape, Mariner, Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit a leak from the power transfer unit (PTU) vent tube bolt. This may be misdiagnosed as a PTU link shaft seal leak. Please verify leak origin and tighten PTU vent tube bolt, before replacing parts. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the PTU fill plug and check fluid level per Workshop Manual (WSM), Section 308-07B. NOTE THE FLUID LEVEL MUST BE EVEN WITH THE BOTTOM OF THE FILLER HOLE WITH THE VEHICLE ON FLAT, LEVEL GROUND. 2. Inspect PTU vent tube bolt for leak. (Figure 1) a. If PTU vent tube bolt leaking - clean bolt contact sur[aces and torque bolt to 120 +/- 19 lb-in (13.5 +/- 2.1 N.m). b. If PTU vent tube bolt not leaking - continue with normal WSM, Section 308-07B diagnosis. NOTE THIS BOLT DOES NOT REQUIRE A WASHER FOR THIS APPLICATION. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-4-4 > Mar > 09 > Drivetrain - Fluid leak From PTU Vent > Page 1249 OPERATION DESCRIPTION TIME 090404A 2005-2009 Escape, 0.5 Hr. Mariner, Escape Hybrid, 2006-2009 Mariner Hybrid: Clean Bolt Contact Surfaces, Includes Time To Check And Adjust PTU Fluid Level DEALER CODING CONDITION BASIC PART NO. CODE 7034 24 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 1255 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0442/P0456/P1450 TSB 10-1-3 02/01/10 HYBRID ONLY - DTCS P0442, P0456 OR P1450 - BUILT ON OR BEFORE 4/6/2009 FORD: 2010 Fusion 2009 Escape MERCURY: 2010 Milan 2009 Mariner This article supersedes TSB 09-9-9 to add a production fix date. ISSUE Some 2009 Escape Hybrid, Mariner Hybrid, 2010 Fusion Hybrid and Milan Hybrid vehicles built on or before 4/6/2009 may exhibit a malfunction indicator light (MIL) accompanied by diagnostic trouble code (DTC) P0442, P0456 or P1450. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Follow the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostic procedures for any DTC code that may be present to ensure the Evaporative Emissions (EVAP) system is functioning properly. 2. When performing EVAP diagnostics on Escape Hybrid and Mariner Hybrid vehicles, the ambient temperature must be greater than 32 °F (0 °C) and the heating ventilation air conditioning (HVAC) system should be set to Defrost. This will provide continuous gasoline engine operation. 3. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 60.11 and higher or 61.01 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 100103A 2010 Fusion Hybrid/Milan 0.3 Hr. Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) 100103A 2009 Escape 0.3 Hr. Hybrid/Mariner Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 1260 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls Sync Software Programming TSB 08-21-2 10/27/08 SYNC SOFTWARE PROGRAMMING SERVICE TIPS FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus 2009 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator 2009 Mark LT MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE The Sync Accessory Protocol Interface Module (APIM) may require updates to add system enhancements, improve system reliability or address consumer issues. The installation or availability of these updates may be made available in two different methods: ^ Downloadable consumer Service Pack updates available through www.SYNCmyride.com website. ^ APIM Programming Using the Integrated Diagnostic System (IDS). The tool and installation requirements vary between these two methods. This information is being provided to supplement current publications, clarify the requirements needed to reprogram or update the APIM module and provide some additional diagnostic/operational system information. ACTION Refer to the Service Tips for details. SERVICE TIPS Downloadable Consumer Service Pack Updates (Available At www.SyncMyRide.com) These Service Pack Updates are for the Consumer Interface Processor (CIP) side of the APIM module only and are customized for each vehicle based on the last reported APIM software level state. The software download process will bundle the appropriate service packs that are required to achieve the desired state. This is why consumers are asked to report back to the website once they have completed the install. NOTE IT IS NOT RECOMMENDED TO REUSE A DOWNLOADED SERVICE PACK ACROSS MULTIPLE VEHICLES. EACH DOWNLOAD IS PACKAGED ACCORDINGLY TO THE CURRENT STATE OF THE VEHICLE THAT THE DOWNLOAD IS INTENDED FOR. NOTE CONSUMERS DO NOT HAVE THE ABILITY TO REMOVE SERVICE PACK UPDATES ONCE THEY ARE INSTALLED. Steps For Consumer's To Update Sync With The Latest Enhancements 1. Prepare universal serial bus (USB) storage drive by: a. Log into their Sync account and select applications and updates to download. b. Locates a portable USB storage drive that they can take to their vehicle. NOTE FOR OWNERS OF MULTIPLE SYNC-EQUIPPED VEHICLES, IT IS STRONGLY RECOMMENDED TO USE A SEPARATE USB DRIVE FOR EACH SYNC-EQUIPPED VEHICLE. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 1265 Dedicating a USB drive to each vehicle's Sync system helps keep each vehicle's download and installation history current and accurate. In addition, as new Sync features and functionalities become available, consumers may decide to install different features on different vehicles. Dedicated USB drives will help maintain the unique applications for each vehicle. 2. Download files by: a. Plug the USB drive into the computer's USB port. b. Select the USB port being used on the computer. c. Confirm choice of USB storage drive. Then click Next. d. After clicking Next, the files will automatically begin downloading. NOTE DO NOT REMOVE THE USB DRIVE UNTIL THE DOWNLOAD IS COMPLETE. THE SCREEN WILL CONFIRM THAT THE DOWNLOAD IS COMPLETE. e. Safely remove the USB storage drive from the computer's USB port by clicking on the Windows personal computer (PC) Safely Remove Hardware icon at the bottom right of the screen, next to the clock. 3. Install files by: a. Insert USB storage drive into the vehicle's Sync USB port. b. Turn on both, the vehicle and radio. NOTE IT IS RECOMMENDED TO HAVE THE VEHICLE RUNNING (WITH PROPER EXHAUST VENTILATION) AND NOT IN THE ACCESSORY MODE. THIS IS TO ENSURE THE VEHICLE'S BATTERY SUPPLY VOLTAGE REMAINS STABLE DURING THE PROGRAMMING PROCESS. c. Select User Device. d. Select Settings. e. Select Install. Display will change to Begin Installation? f. Select Yes. Installing file - will display on the screen. NOTE DO NOT REMOVE THE USB DRIVE WHILE THE INSTALLATION IS IN PROGRESS. g. Upon completion of downloading of files, Installation Complete will display on the Sync screen. h. The Sync voice will say, Installation complete. Sync may also say, The system will now reboot. Please wait a few moments before using the system. Installation Complete will remain on the Sync display until you exit the installation mode. i. Select the Menu radio button to exit installation mode. j. Remove the USB storage drive. k. Consumer takes their USB storage drive back to their computer to report the successful install. (This feature allows for tracking and determining if the consumers vehicle has a newer version available for downloading or not.) NOTE ADDITIONAL INFORMATION AND DETAILS ARE AVAILABLE ON THE SYNCMYRIDE.COM WEBSITE. REGISTERED SYNC OWNERS WILL SEE VEHICLE SPECIFIC DETAILS AND DIRECTIONS BASED ON THEIR VEHICLE'S OPTION CONTENT. APIM Programming Using IDS This method programs both, the Vehicle Interface Processor (VIP) (through the data link connector) and CIP (through the USB port), portions of the APIM module. NOTE Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 1266 SOFTWARE PACKAGES OBTAINED THROUGH THE PROFESSIONAL TECHNICIAN SOCIETY (PTS) WEBSITE CONTAINS BOTH, VIP AND CIP FILES, THESE DO NOT NEED TO BE INSTALLED IN SEQUENCE LIKE THE CONSUMER DOWNLOAD SERVICE PACK UPDATES, BUT THE ENTIRE PACKAGE MUST BE INSTALLED DURING REPROGRAMMING FOR PROPER OPERATION. THESE SOFTWARE PACKAGES ARE MUCH LARGER IN SIZE AND CONTAIN ALL THE PREVIOUS LEVELS OF ENHANCEMENTS AND UPDATES AS WELL AS ANY ADDITIONAL ENHANCEMENTS AND UPDATES FOR BOTH THE VIP AND CIP PROCESSORS LOCATED IN THE APIM MODULE. NOTE YOU WILL NOT HAVE THE ABILITY TO RESTORE THE PREVIOUS LEVEL OF SYNC OPERATING SOFTWARE ONCE THE APIM MODULE HAS BEEN SUCCESSFULLY UPDATED TO THE NEXT HIGHER LEVEL. NOTE If a new APIM is being installed, install the new APIM before carrying out the following procedure. For additional information, refer to Workshop Manual (WSM), Section 415-00. It is recommended to install a battery charger to the vehicles battery and set at the low charge setting and insure the PC being used for reprogramming is fully charged or plugged into a power source prior to starting the reprogramming process. 1. Turn the ignition key to the On position. 2. Turn the audio control module (ACM) on. 3. Connect the scan tool to the data link connector (DLC). 4. Connect one end of the USB male-A to male-A cable Rotunda part number CCMUSB2-AM-AM-10 (1-800-Rotunda option 6) or equivalent to the scan tool. Compatible cables. (Figures 1) Non-compatible cables. (Figure 2) 5. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 6. From the technician service publication website, run OASIS using Quick Start or by manually entering the vehicle identification number (VIN). 7. From the OASIS tab, select the Sync/APIM bullet. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 1267 8. Select the Read APIM button to verify the current APIM VIP and CIP software levels. NOTE DO NOT DISCONNECT THE VEHICLE COMMUNICATION MODULE (VCM) OR USB CABLES DURING APIM PROGRAMMING. 9. Select the desired software level from the list of available software for programming then select the Program APIM button to begin the APIM programming process. Enter the APIM As-Built data if prompted. a. When only the CIP is being programmed, select cancel when prompted whether or not to program the VIP. b. When the VIP is programmed, the CIP will be programmed automatically. 10. The Sync/APIM application downloads the software into the APIM and displays Programming has been completed successfully. 11. Test the audio system for correct operation. PC requirements for successful reprogramming an APIM module. Ford And LIM Logon Issues - Including Proper Browser Settings The following list will have you check various computer settings to insure your PC is set to the proper configuration for reprogramming an APIM module. NOTE CHANGES TO PC SETTINGS MAY REQUIRE ADMINISTRATOR ACCESS. 1. Do not use a customized browser like AOL, it will not work. Please use Internet Explorer (IE) version 5.5 5P2, 6.0, or higher. 2. Log into website. 3. Navigate to PTS (Professional Technician Society) under the Technical Tools on the Parts and Service tab. 4. Check IE settings by completing the following: a. Preliminary Checks. NOTE THESE INSTRUCTIONS APPLY TO WINDOWS XP MACHINES WITH 5P2 AND IE 6.0 AND ABOVE. (1) Open IE, select Tools at the top of the screen and select Security. (2) Click on the Internet Zone, and find Navigate Sub-frames across different domains and enable this function. (3) Then click OK, system may ask you if you want to accept these function please select Yes. (4) Check the Windows Firewall to make sure it is turned off by: (a) Selecting the Start button. (b) Select Control Panel. (c) Select Windows Firewall (if you do not see the icon, make sure you are using Classic View) and set to off. (5) Check Windows Pop-up Blocker to make sure it is turned off. (a) Open IE. (b) Select Tools at the top of the screen. (c) Select Pop-up Blocker and turn it off. (6) Remove any add-on toolbars such as Google or Yahoo toolbars, as these have additional built in pop-up blockers. (7) Verify that any third party anti-virus, anti-spyware, firewall, or internet security software is temporarily disabled. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 1268 b. Browser Settings - Open IE and select Internet Options under the Tools heading. (1) Select the General tab (2) Select Delete Files and check the Delete all offline content and select OK (3) Select Delete Cookies and click OK (4) Select Clear History and select Yes. (5) Click on the Security tab. (6) Click on the Trusted Sites icon. (7) Click on Sites. (8) In the box below add this website to the zone type in - website. (9) Ensure that required server verification (https:) for all sites in this zone is not checked. (10) Click the Add button. (11) Click the Close button. (12) Re-select the Security tab and select Custom Level. (13) Under Reset Custom Settings, pull down and Reset to: Low, select Reset, select Yes and then OK. NOTE IF RUNNING OASIS ON IE 7.0, RESET TO: MEDIUM-LOW. ALSO, UNDER SETTINGS, SCROLL TO NAVIGATE SUB-FRAMES ACROSS DIFFERENT DOMAINS, SET TO ENABLED AND CLICK OK. (14) Select the Privacy tab, and move the slider to Low. (15) Click on the Advanced, check the box Override automatic cookie handling and check the box to Always allow session cookies' and click OK. (16) Select the Advanced tab and scroll down to HTP 1.1 settings; make sure both options under this section are checked. (17) Scroll down to Security section and make sure the following are checked: (a) Empty Temporary Internet folder when browser is closed. (b) Use SSL 2.0. (c) Use SSL 3.0. (d) Use TLS 1.0. (e) Select Apply and then click on OK. 5. Close all browsers and reboot the computer to have the browser settings take affect properly. The browser settings have now been setup correctly as per Ford Browser settings recommendations. Additional PC Security Settings (May Or May Not Be Required - Depends On Operating System) Changes to PC Security Settings may require Administrator access. 1. Check for Information Bar near top of IE page stating - This website wants to run the following add-ons. 2. Click on Information Bar and select Run ActiveX Controls or Temporarily Allow Pop-ups depending on your operating system. 3. Click on Retry button to refresh information. (May not be required on some operating systems) PC and Server Troubleshooting (Optional) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 1269 ^ If you wish to test another browser for web-based training only, download the free version of Opera at www.Opera.com. ^ For web-based training sound problems, make sure your firewall allows downloading sound file types such as MP3. ^ If you have installed special search and add-on programs such as Gator or Bonzi please remove them. ^ If you have a router, make sure that port 443 is open for Secure Socket Layer (SSL), and ports 80 and 8080 are open for HTTP. ^ Internet access uses a caching or proxy server. Make sure the caching/proxy servers are set to automatically detect settings. Contact your local network administrator and/or your Internet service provider and have them turn off the caching on any and all caching proxy servers for the following: ^ Uniform Resource Locator (URL): www.proservicetech.com or ford website Additional Sync Related Service Tips 1. Performing a Master Reset of the APIM module or removing and restoring the Keep Alive Power circuit fuse (refer to the appropriate wiring manual) for 3-minutes, prior to reprogramming will restore the factory APIM defaults. This can reduce the possibilities of corrupt files, that may have been transferred into the APIM modules memory, from interfering with the reprogramming of the CIP portion of the APIM module. 2. Non-factory installed items that can cause background noise, wind noise or obstruct the voice path to the Sync system's microphone, will reduce the reliability or accuracy of the consumer's voice commands or speech being recognized properly. Some examples may include but are not limited to: ^ Objects hanging from the rear view mirror that may make noise or obstruct the system microphone located on the mirror. ^ Bug shields. ^ Roof mounted accessories. ^ Damaged window moldings. ^ Non-factory installed overhead consoles or sun-visor storage compartments that obstruct the voice path to the systems microphone. (It is recommended when diagnosing voice recognition or phone call sound quality issues to eliminate these types of items before replacing any system components) 3. Remote Starts may prevent the Automatic Discovery Process, of previously paired phones, from connecting with the consumer's phone as it may be outside of the device's Bluetooth reception range. Once the vehicle is started remotely, the Sync system automatically begins to search for previously paired phones; eventually this process will time out if the customers phone does not enter the vehicle prior to the expiration of this internal timer, resulting in the vehicle Sync not automatically recognize the phone and pair with it. If this occurs, once the customer enters the vehicle, the consumer will be required to manually connect the phone through the Sync menus if they would like to use the hands free phone features. NOTE THE CONSUMER WILL NOT BE REQUIRED TO PAIR THE PHONE AGAIN. 4. When Reprogramming APIM modules, it is strongly recommended to use a hard wired internet connection if possible, due to the APIM program file sizes. If a wired internet connection is not available, it is recommended to access the PTS website and download the latest Sync software files from the Tech Central tab prior to reprogramming. This will reduce the overall reprogramming time when you are connected to the vehicle. If error messages appear during the reprogramming process that indicate errors with the VIP or CIP file/image, comparing the saved file/image by checking the file size, between your PC/IDS with the available file/image size indicated in the PTS description can help determine if the file may be corrupt or damaged. If this has occurred or is suspected, re-download the file/image and select Yes when asked Do you want to replace it? 5. Always diagnose and repair any DTC's for the Audio system or any module communication related faults prior to APIM reprogramming. WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 1275 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 1280 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 1285 Dedicating a USB drive to each vehicle's Sync system helps keep each vehicle's download and installation history current and accurate. In addition, as new Sync features and functionalities become available, consumers may decide to install different features on different vehicles. Dedicated USB drives will help maintain the unique applications for each vehicle. 2. Download files by: a. Plug the USB drive into the computer's USB port. b. Select the USB port being used on the computer. c. Confirm choice of USB storage drive. Then click Next. d. After clicking Next, the files will automatically begin downloading. NOTE DO NOT REMOVE THE USB DRIVE UNTIL THE DOWNLOAD IS COMPLETE. THE SCREEN WILL CONFIRM THAT THE DOWNLOAD IS COMPLETE. e. Safely remove the USB storage drive from the computer's USB port by clicking on the Windows personal computer (PC) Safely Remove Hardware icon at the bottom right of the screen, next to the clock. 3. Install files by: a. Insert USB storage drive into the vehicle's Sync USB port. b. Turn on both, the vehicle and radio. NOTE IT IS RECOMMENDED TO HAVE THE VEHICLE RUNNING (WITH PROPER EXHAUST VENTILATION) AND NOT IN THE ACCESSORY MODE. THIS IS TO ENSURE THE VEHICLE'S BATTERY SUPPLY VOLTAGE REMAINS STABLE DURING THE PROGRAMMING PROCESS. c. Select User Device. d. Select Settings. e. Select Install. Display will change to Begin Installation? f. Select Yes. Installing file - will display on the screen. NOTE DO NOT REMOVE THE USB DRIVE WHILE THE INSTALLATION IS IN PROGRESS. g. Upon completion of downloading of files, Installation Complete will display on the Sync screen. h. The Sync voice will say, Installation complete. Sync may also say, The system will now reboot. Please wait a few moments before using the system. Installation Complete will remain on the Sync display until you exit the installation mode. i. Select the Menu radio button to exit installation mode. j. Remove the USB storage drive. k. Consumer takes their USB storage drive back to their computer to report the successful install. (This feature allows for tracking and determining if the consumers vehicle has a newer version available for downloading or not.) NOTE ADDITIONAL INFORMATION AND DETAILS ARE AVAILABLE ON THE SYNCMYRIDE.COM WEBSITE. REGISTERED SYNC OWNERS WILL SEE VEHICLE SPECIFIC DETAILS AND DIRECTIONS BASED ON THEIR VEHICLE'S OPTION CONTENT. APIM Programming Using IDS This method programs both, the Vehicle Interface Processor (VIP) (through the data link connector) and CIP (through the USB port), portions of the APIM module. NOTE Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 1286 SOFTWARE PACKAGES OBTAINED THROUGH THE PROFESSIONAL TECHNICIAN SOCIETY (PTS) WEBSITE CONTAINS BOTH, VIP AND CIP FILES, THESE DO NOT NEED TO BE INSTALLED IN SEQUENCE LIKE THE CONSUMER DOWNLOAD SERVICE PACK UPDATES, BUT THE ENTIRE PACKAGE MUST BE INSTALLED DURING REPROGRAMMING FOR PROPER OPERATION. THESE SOFTWARE PACKAGES ARE MUCH LARGER IN SIZE AND CONTAIN ALL THE PREVIOUS LEVELS OF ENHANCEMENTS AND UPDATES AS WELL AS ANY ADDITIONAL ENHANCEMENTS AND UPDATES FOR BOTH THE VIP AND CIP PROCESSORS LOCATED IN THE APIM MODULE. NOTE YOU WILL NOT HAVE THE ABILITY TO RESTORE THE PREVIOUS LEVEL OF SYNC OPERATING SOFTWARE ONCE THE APIM MODULE HAS BEEN SUCCESSFULLY UPDATED TO THE NEXT HIGHER LEVEL. NOTE If a new APIM is being installed, install the new APIM before carrying out the following procedure. For additional information, refer to Workshop Manual (WSM), Section 415-00. It is recommended to install a battery charger to the vehicles battery and set at the low charge setting and insure the PC being used for reprogramming is fully charged or plugged into a power source prior to starting the reprogramming process. 1. Turn the ignition key to the On position. 2. Turn the audio control module (ACM) on. 3. Connect the scan tool to the data link connector (DLC). 4. Connect one end of the USB male-A to male-A cable Rotunda part number CCMUSB2-AM-AM-10 (1-800-Rotunda option 6) or equivalent to the scan tool. Compatible cables. (Figures 1) Non-compatible cables. (Figure 2) 5. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 6. From the technician service publication website, run OASIS using Quick Start or by manually entering the vehicle identification number (VIN). 7. From the OASIS tab, select the Sync/APIM bullet. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 1287 8. Select the Read APIM button to verify the current APIM VIP and CIP software levels. NOTE DO NOT DISCONNECT THE VEHICLE COMMUNICATION MODULE (VCM) OR USB CABLES DURING APIM PROGRAMMING. 9. Select the desired software level from the list of available software for programming then select the Program APIM button to begin the APIM programming process. Enter the APIM As-Built data if prompted. a. When only the CIP is being programmed, select cancel when prompted whether or not to program the VIP. b. When the VIP is programmed, the CIP will be programmed automatically. 10. The Sync/APIM application downloads the software into the APIM and displays Programming has been completed successfully. 11. Test the audio system for correct operation. PC requirements for successful reprogramming an APIM module. Ford And LIM Logon Issues - Including Proper Browser Settings The following list will have you check various computer settings to insure your PC is set to the proper configuration for reprogramming an APIM module. NOTE CHANGES TO PC SETTINGS MAY REQUIRE ADMINISTRATOR ACCESS. 1. Do not use a customized browser like AOL, it will not work. Please use Internet Explorer (IE) version 5.5 5P2, 6.0, or higher. 2. Log into website. 3. Navigate to PTS (Professional Technician Society) under the Technical Tools on the Parts and Service tab. 4. Check IE settings by completing the following: a. Preliminary Checks. NOTE THESE INSTRUCTIONS APPLY TO WINDOWS XP MACHINES WITH 5P2 AND IE 6.0 AND ABOVE. (1) Open IE, select Tools at the top of the screen and select Security. (2) Click on the Internet Zone, and find Navigate Sub-frames across different domains and enable this function. (3) Then click OK, system may ask you if you want to accept these function please select Yes. (4) Check the Windows Firewall to make sure it is turned off by: (a) Selecting the Start button. (b) Select Control Panel. (c) Select Windows Firewall (if you do not see the icon, make sure you are using Classic View) and set to off. (5) Check Windows Pop-up Blocker to make sure it is turned off. (a) Open IE. (b) Select Tools at the top of the screen. (c) Select Pop-up Blocker and turn it off. (6) Remove any add-on toolbars such as Google or Yahoo toolbars, as these have additional built in pop-up blockers. (7) Verify that any third party anti-virus, anti-spyware, firewall, or internet security software is temporarily disabled. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 1288 b. Browser Settings - Open IE and select Internet Options under the Tools heading. (1) Select the General tab (2) Select Delete Files and check the Delete all offline content and select OK (3) Select Delete Cookies and click OK (4) Select Clear History and select Yes. (5) Click on the Security tab. (6) Click on the Trusted Sites icon. (7) Click on Sites. (8) In the box below add this website to the zone type in - website. (9) Ensure that required server verification (https:) for all sites in this zone is not checked. (10) Click the Add button. (11) Click the Close button. (12) Re-select the Security tab and select Custom Level. (13) Under Reset Custom Settings, pull down and Reset to: Low, select Reset, select Yes and then OK. NOTE IF RUNNING OASIS ON IE 7.0, RESET TO: MEDIUM-LOW. ALSO, UNDER SETTINGS, SCROLL TO NAVIGATE SUB-FRAMES ACROSS DIFFERENT DOMAINS, SET TO ENABLED AND CLICK OK. (14) Select the Privacy tab, and move the slider to Low. (15) Click on the Advanced, check the box Override automatic cookie handling and check the box to Always allow session cookies' and click OK. (16) Select the Advanced tab and scroll down to HTP 1.1 settings; make sure both options under this section are checked. (17) Scroll down to Security section and make sure the following are checked: (a) Empty Temporary Internet folder when browser is closed. (b) Use SSL 2.0. (c) Use SSL 3.0. (d) Use TLS 1.0. (e) Select Apply and then click on OK. 5. Close all browsers and reboot the computer to have the browser settings take affect properly. The browser settings have now been setup correctly as per Ford Browser settings recommendations. Additional PC Security Settings (May Or May Not Be Required - Depends On Operating System) Changes to PC Security Settings may require Administrator access. 1. Check for Information Bar near top of IE page stating - This website wants to run the following add-ons. 2. Click on Information Bar and select Run ActiveX Controls or Temporarily Allow Pop-ups depending on your operating system. 3. Click on Retry button to refresh information. (May not be required on some operating systems) PC and Server Troubleshooting (Optional) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Transfer Case: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 1289 ^ If you wish to test another browser for web-based training only, download the free version of Opera at www.Opera.com. ^ For web-based training sound problems, make sure your firewall allows downloading sound file types such as MP3. ^ If you have installed special search and add-on programs such as Gator or Bonzi please remove them. ^ If you have a router, make sure that port 443 is open for Secure Socket Layer (SSL), and ports 80 and 8080 are open for HTTP. ^ Internet access uses a caching or proxy server. Make sure the caching/proxy servers are set to automatically detect settings. Contact your local network administrator and/or your Internet service provider and have them turn off the caching on any and all caching proxy servers for the following: ^ Uniform Resource Locator (URL): www.proservicetech.com or ford website Additional Sync Related Service Tips 1. Performing a Master Reset of the APIM module or removing and restoring the Keep Alive Power circuit fuse (refer to the appropriate wiring manual) for 3-minutes, prior to reprogramming will restore the factory APIM defaults. This can reduce the possibilities of corrupt files, that may have been transferred into the APIM modules memory, from interfering with the reprogramming of the CIP portion of the APIM module. 2. Non-factory installed items that can cause background noise, wind noise or obstruct the voice path to the Sync system's microphone, will reduce the reliability or accuracy of the consumer's voice commands or speech being recognized properly. Some examples may include but are not limited to: ^ Objects hanging from the rear view mirror that may make noise or obstruct the system microphone located on the mirror. ^ Bug shields. ^ Roof mounted accessories. ^ Damaged window moldings. ^ Non-factory installed overhead consoles or sun-visor storage compartments that obstruct the voice path to the systems microphone. (It is recommended when diagnosing voice recognition or phone call sound quality issues to eliminate these types of items before replacing any system components) 3. Remote Starts may prevent the Automatic Discovery Process, of previously paired phones, from connecting with the consumer's phone as it may be outside of the device's Bluetooth reception range. Once the vehicle is started remotely, the Sync system automatically begins to search for previously paired phones; eventually this process will time out if the customers phone does not enter the vehicle prior to the expiration of this internal timer, resulting in the vehicle Sync not automatically recognize the phone and pair with it. If this occurs, once the customer enters the vehicle, the consumer will be required to manually connect the phone through the Sync menus if they would like to use the hands free phone features. NOTE THE CONSUMER WILL NOT BE REQUIRED TO PAIR THE PHONE AGAIN. 4. When Reprogramming APIM modules, it is strongly recommended to use a hard wired internet connection if possible, due to the APIM program file sizes. If a wired internet connection is not available, it is recommended to access the PTS website and download the latest Sync software files from the Tech Central tab prior to reprogramming. This will reduce the overall reprogramming time when you are connected to the vehicle. If error messages appear during the reprogramming process that indicate errors with the VIP or CIP file/image, comparing the saved file/image by checking the file size, between your PC/IDS with the available file/image size indicated in the PTS description can help determine if the file may be corrupt or damaged. If this has occurred or is suspected, re-download the file/image and select Yes when asked Do you want to replace it? 5. Always diagnose and repair any DTC's for the Audio system or any module communication related faults prior to APIM reprogramming. WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Capacity Power Transfer Unit ............................................................................................................................. ............................................ 12.0 ounces (0.35 liters) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1292 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ................................................................................................................................................ SAE 75W-140 High Performance Rear Axle Lubricant Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil ............................................................................................................................................ ......................................................... 5.0 qts. (4.73 L) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1297 Engine Oil: Fluid Type Specifications Ford Part Name US .......................................................................................................................................... Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Canada ................................................................................................................................................... Motorcraft SAE 5W-20 Super Premium Motor Oil Ford Part Number US .......................................................................................................................... ........................................................................................ X0-5W20-QSP Canada .............................. .............................................................................................................................................................. ......... CX0-5W20-LSP12 Ford Specifications ....................................................................................................................................... WSS-M2C930-A with API Certification Mark Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Power Steering This vehicle is equipped with a Electric Power Assisted Steering (EPAS) System. There is no fluid reservoir to check or fill. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Item..............................................................................................................................R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification........................................... ......................................................................................................................................................WS H-M17B19-A Fill Capacity.................................................................................................................... ...................................................................1.08 kg (38 oz) (2.38 lb) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1305 Refrigerant: Fluid Type Specifications Item..............................................................................................................................R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification........................................... ......................................................................................................................................................WS H-M17B19-A Fill Capacity.................................................................................................................... ...................................................................1.08 kg (38 oz) (2.38 lb) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1306 Refrigerant: Testing and Inspection Refrigerant Identification Testing Refrigerant Identification 1. NOTE: A Refrigerant Blend Identifier with Printer must be used to identify gas samples taken directly from the refrigeration system or storage containers prior to recovering or charging the refrigerant system. Follow the instructions included with the Refrigerant Blend Identifier with Printer to obtain the sample for testing. 2. The Refrigerant Blend Identifier with Printer will display one of the following: - If the purity level of R-134a is 98% or greater by weight, the green PASS LED will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons and air will be displayed on the digital display. - If refrigerant R-134a does not meet the 98% purity level, the red FAIL LED will light and an alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22 and hydrocarbons will be displayed on the digital display. - If hydrocarbon concentrations are 2% or greater by weight, the red FAIL LED will light, "Hydrocarbon High" will be displayed on the digital display, and an alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22 and hydrocarbons will also be displayed on the digital display. 3. The percentage of air contained in the sample will be displayed if the R-134a content is 98% or greater. The Refrigerant Blend Identifier with Printer eliminates the effect of air when determining the refrigerant sample content because air is not considered a contaminant, although air can affect A/C system performance. When the Refrigerant Blend Identifier with Printer has determined that a refrigerant source is pure (R-134a is 98% or greater by weight) and air concentration levels are 2% or greater by weight, it will prompt the user if an air purge is desired. 4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the refrigerant is indeed contaminated. Contaminated Refrigerant Handling NOTICE: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a recovery/recycling equipment. Recovery of contaminated refrigerant will contaminate the recovered refrigerant supply and may damage the recovery/recycling equipment. NOTE: A new suction accumulator or receiver/drier must be installed as directed by the A/C system flushing procedure. 1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant only. - If this equipment is not available, contact an A/C service facility in the area with the correct equipment to carry out this service. 2. Determine and correct the cause of the customers initial concern. 3. Flush the A/C system. 4. Dispose of the contaminated refrigerant in accordance with all federal, state and local regulations. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging Refrigerant: Service and Repair Air Conditioning (A/C) System Recovery, Evacuation and Charging Air Conditioning (A/C) System Recovery, Evacuation and Charging Refrigerant System Recovery NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If the vehicle's A/C refrigerant is contaminated, refer the customer to the service Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1309 facility that carried out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment manufacturer procedures and instructions. NOTE: Ford Motor Company recommends the use of R-134a refrigerant management equipment that meets the requirements of the SAE J2788 standard. NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out recovery. If a R-134a Refrigerant Management Machine is not available, refrigerant system recovery may be accomplished using a separate recovery station. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Prior to recovering, the purity of the refrigerant must be verified. For additional information, refer to Refrigerant Identification Testing . 2. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. Note the amount of oil removed during the refrigerant recovery (if any). Add that same amount back into the system once repairs are complete. 4. Once the R-134a Refrigerant Management Machine has recovered the refrigerant, switch OFF the power supply. 5. Allow the system to set for about 2 minutes, and observe the system vacuum reading. If the vacuum is not lost, disconnect the recovery equipment. 6. If the system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable for 2 minutes. 7. Carry out the required repairs. Refrigerant System Evacuation Using a R-134a Refrigerant Management Machine NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out recovery, evacuation and charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, evacuation may be accomplished using a separate Vacuum Pump and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of 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. 3. Turn OFF the Vacuum Pump. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Evacuation Using a R-134a Manifold Gauge Set and Vacuum Pump NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out evacuation of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, refrigerant system evacuation may be accomplished using a separate Vacuum Pump and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Connect the R-134a Manifold Gauge Set to the low-side and high-side service gauge port valves. 2. Connect the center (yellow) hose from the R-134a Manifold Gauge Set to the suction port on the Vacuum Pump. 3. Open all valves on the R-134a Manifold Gauge Set and both service gauge port valves. 4. Turn on the Vacuum Pump and evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1310 101.1 kPa (30 in-Hg) as possible. Continue to operate the Vacuum Pump for a minimum of 45 minutes. 5. Close the high-side and low-side valves on the R-134a Manifold Gauge Set (not the service gauge port valves) and turn OFF the Vacuum Pump. 6. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Charging Using a R-134a Refrigerant Management Machine NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, refrigerant system charging may be accomplished using a separate Automatic Refrigerant Charging Meter and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Refrigerant Oil Adding See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Adding. 2. Connect a R-134a Refrigerant Management Machine to the low-side and high-side service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions provided by the equipment manufacturer. Refrigerant System Charging Using a R-134a Manifold Gauge Set and Automatic Refrigerant Charging Meter NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, refrigerant system charging may be accomplished using a separate Automatic Refrigerant Charging Meter and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Refrigerant Oil Adding See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Adding. 2. Assemble the R-134a Manifold Gauge Set, Automatic Refrigerant Charging Meter and R-134a supply tank following the Automatic Refrigerant Charging Meter operating instructions. 3. Charge the refrigerant system following the Automatic Refrigerant Charging Meter operating instructions. 4. If the refrigerant flow stops before the refrigerant charge is complete, start the engine, select MAX A/C operation and allow the refrigerant charge to complete. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1311 Refrigerant: Service and Repair Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation WARNING: Use extreme care and observe all safety and service precautions related to the use of refrigerants as outlined on refrigerant tank and on recovery and charging equipment. Failure to follow these instructions may result in serious personal injury. NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If the vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment manufacturer's procedures and instructions. NOTICE: On vehicles being serviced for an internal compressor or desiccant failure, a new suction accumulator or receiver/drier, Thermostatic Expansion Valve (TXV) or evaporator core orifice and any hoses containing mufflers must be installed prior to filtering the Air Conditioning (A/C) system. Internal plumbing of these devices makes it impossible to correctly remove any foreign material. These components are typically discarded after A/C system contamination. Hoses without mufflers can normally be reused unless they are clogged with foreign material. The filter is intended for use on one vehicle only. 1. Orient the filter inlet toward the A/C condenser core. 2. NOTICE: The flexible extension adapters included in the A/C Flush Adapter Kit are designed for low-pressure flushing and are not designed for use with a charged refrigerant system. Do not make the condenser fitting connections using the flexible extension adapters or damage to the adapters and loss of refrigerant will occur. NOTE: The F8VZ-19E773-AB pancake filter is not permanently installed and will be removed at the end of this procedure. Disconnect the condenser outlet fitting and temporarily install the pancake filter between the 2 halves of the fitting. - Use flexible refrigerant hose of 17,238 kPa (2,500 psi) burst rating. - Make the connections using the correct adapters from the A/C Flush Adapter Kit and/or A/C Flush and Purge Fitting Kit. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1312 3. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Refrigerant Oil Adding See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Adding. 4. Evacuate and charge the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. 5. Check all refrigerant system hoses, lines and the position of the newly installed filters to be sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 6. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Select A/C operation and set the blower motor speed to maximum. Start the engine and let it idle briefly. Make sure the A/C system is operating correctly. 7. Gradually bring the engine up to 1,200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1,000 rpm). Set the engine at 1,200 rpm and run it for one hour with the A/C system operating. 8. Stop the engine. 9. Recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. 10. Remove the adapters, flexible hoses and pancake filter from between the condenser and the condenser to evaporator tube. 11. Discard the pancake filter. It can be used one time only. 12. Reconnect the condenser outlet fitting. 13. Evacuate, charge and leak-test the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Item.........................................................................................................................................PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D Specification............................................... ..................................................................................................................................................WSHM1C231-B Fill Capacity........................................................................................................................ ....................................325 ml (11 fl oz) See: Service and Repair Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1317 Refrigerant Oil: Fluid Type Specifications Item.........................................................................................................................................PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D Specification............................................... ..................................................................................................................................................WSHM1C231-B Fill Capacity........................................................................................................................ ....................................325 ml (11 fl oz) See: Service and Repair Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1318 Refrigerant Oil: Service and Repair Refrigerant Oil Adding Refrigerant Oil Adding NOTE: 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, some of the PAG 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. Refer to the chart below for refrigerant oil adding amounts and methods of installation. a If an excessive amount of PAG oil is lost due to a hose rupture/separation or other damage, the total system PAG oil capacity must be added. b The amount specified may be used for one or multiple O-ring leak repairs. Do not multiply the PAG oil amount by the number of O-ring leaks being repaired. Adding Refrigerant Oil After A/C Compressor Replacement Service A/C compressors shipped without clutch and pulley 1. Rotate the A/C compressor shaft 6 to 8 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 oz), pour the same amount plus 30 ml (1 oz) of clean PAG Refrigerant Compressor Oil (R-134a Systems) (YN-12-D) WSH M1C231-B or equivalent into the new A/C compressor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1319 - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 oz), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent 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 oz), pour 85 ml (3 oz) of clean A/C Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. Service A/C compressors shipped with clutch and pulley 2. Rotate the old A/C compressor shaft 6 to 8 revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is less than 89 ml (3 oz), remove 118 ml (4 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is 89 ml (3 oz), remove 89 ml (3 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is 118 ml (4 oz), remove 59 ml (2 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is 148 ml (5 oz), remove 29 ml (1 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is greater than 148 ml (5 oz), remove 0 ml (0 oz) from the new A/C compressor. Adding Refrigerant Oil After New Suction Accumulator or Receiver/Drier Replacement NOTE: This refrigerant oil adding method is to be used when a new suction accumulator or receiver drier only has been installed. If a new A/C compressor and evaporator core orifice or TXV have also been installed due to system contamination, refer to the appropriate heading. 1. Drill one 12.7 mm (1/2 in) hole in the old suction accumulator or receiver/drier cylinder and drain the oil into a clean measuring cup. 2. Add the same quantity of new PAG oil, plus the amount collected during refrigerant recovery and 60 ml (2 fl oz). Adding Refrigerant Oil After Multiple Component Replacement After A/C System Contamination NOTE: This refrigerant oil adding method is to be used when a new A/C compressor, suction accumulator or receiver drier and evaporator core orifice or TXV have been installed due to system contamination and the A/C system has been flushed. NOTE: Service A/C compressors are shipped without refrigerant oil. 1. Add 60 ml (2 fl oz) directly to the new A/C compressor suction port. 2. Inject the total vehicle PAG oil capacity minus 60 ml (2 fl oz) to the low-side service port during system charging. For the total PAG oil capacity specification, refer to the Specifications table. Oil Injection Using a Dye/Lubricant Injector NOTE: If fluorescent leak detection dye is also to be added during A/C charging, the dye may be added to the dye/lubricant injector, from the R-134a Loop/Add On Injector Kit-Set, along with the PAG oil. 1. Evacuate the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. 2. Assemble the dye/lubricant injector and the correct adapters from the R-134a Loop/Add On Injector Kit-Set to match the amount of refrigerant compressor oil to be injected. 3. Verify that all the valves on the dye/lubricant injector are closed. 4. Fill the dye/lubricant injector with the correct amount of clean, new PAG oil. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1320 5. Install the dye/lubricant injector between the low-side service gauge port valve and the refrigerant service station or manifold gauge set. 6. Open all valves and charge the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding Brake Bleeding: Service and Repair Component Bleeding Master Cylinder Component Bleeding Master Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. Hybrid vehicles 1. Disconnect the brake tubes from the master cylinder. 2. Install short brake tubes onto the primary and secondary ports of the master cylinder with the ends submerged in the brake master cylinder reservoir. 3. Fill the brake reservoir with clean, specified brake fluid. 4. NOTE: On hybrid vehicles, the brake booster push rod has an elongated slot that attaches to the brake pedal with a clevis pin. The elongated slot allows for a small amount of pedal travel (free play) to occur without the brake pedal applying pressure on the booster push rod. When performing a bleed procedure, it is important to push the pedal through the air gap, so that the clevis pin is contacting the brake booster push rod. Except when required by the scan tool, the ignition key must remain off during the bleed procedure to allow minimal force required to push through the gap. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air bubbles. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1325 5. Remove the short brake tubes and install the brake outlet tubes. - Tighten the master cylinder brake tube fittings to specifications. Refer to Specifications. Non-hybrid vehicles 6. Place a box-end wrench on the master cylinder bleeder screw and attach a rubber drain hose to the bleeder screw. Submerge the free end of the rubber hose into the master cylinder reservoir. 7. Fill the master cylinder reservoir with clean, specified brake fluid. 8. Have an assistant pump the brake pedal until clear fluid flows from the rubber hose, without air bubbles. 9. Tighten the bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. All vehicles 10. Bleed the brake system. For additional information, refer to Brake System Bleeding See: Brake System Bleeding. Brake Caliper Component Bleeding Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was disconnected or installed new. 1. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1326 2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 5. Apply brakes several times to verify correct brake operation. Wheel Cylinder Component Bleeding Wheel Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: It is not necessary to do a complete brake system bleed if only the wheel cylinder was disconnected or installed new. 1. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1327 - Refill the brake master cylinder reservoir as necessary. 4. Tighten the bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 5. Apply brakes several times to verify correct brake operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1328 Brake Bleeding: Service and Repair Brake System Bleeding Brake System Bleeding Manual Bleeding - Non-Hybrid Vehicles Only WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: Pressure bleeding the brake system is preferred to manual bleeding. NOTE: Due to the complexity of the fluid path within the hybrid brake system, it is necessary to pressure bleed this system. 1. Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake master cylinder reservoir with clean, specified brake fluid. 2. Remove the RR bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the RR bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 3. Have an assistant pump and then hold firm pressure on the brake pedal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1329 4. Loosen the RR bleeder screw until a stream of brake fluid comes out. While an assistant maintains pressure on the brake pedal, tighten the RR bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 5. Tighten the RR bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 6. Repeat Steps 2 through 5 for the LR bleeder screw. 7. Remove the RF bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the RF bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 8. Have an assistant pump and then hold firm pressure on the brake pedal. 9. Loosen the RF bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RF bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 10. Tighten the RF bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 11. Repeat Steps 7 through 10 for the LF bleeder screw. Pressure Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new. NOTE: Pressure bleed the brake system at 207-345 kPa (30-50 psi). NOTE: Due to the complexity of the fluid path within the hybrid brake system, it is necessary to pressure bleed this system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1330 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with clean, specified brake fluid. 2. 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 the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Make sure the bleeder tank contains enough clean, specified brake fluid to complete the bleeding operation. Remove the RR bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the RR bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 4. Open the valve on the bleeder tank. - Apply 207-345 kPa (30-50 psi) to the brake system. 5. Loosen the RR bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RR bleeder screw to specifications. Refer to Specifications. Remove the rubber hose. 6. Continue bleeding the rest of the system, going in order from the LR bleeder screw to the RF bleeder screw, ending with the LF bleeder screw. - Tighten the brake caliper and wheel cylinder bleeder screws to specifications. Refer to Specifications. 7. Close the bleeder tank valve and release the pressure. Remove the tank hose from the adapter and remove the adapter. Fill the reservoir with clean, specified brake fluid and install the reservoir cap. 8. NOTE: On hybrid vehicles, the brake booster push rod has an elongated slot that attaches to the brake pedal with a clevis pin. The elongated slot allows for a small amount of pedal travel (free play) to occur without the brake pedal applying pressure on the booster push rod. When performing a bleed procedure, it is important to push the pedal through the air gap, so that the clevis pin is contacting the brake booster push rod. Except when required by the scan tool, the ignition key must remain off during the bleed procedure to allow minimal force required to push through the gap. With the ignition off, press the brake pedal through the gap to seat the clevis pin against the brake booster push rod and then confirm the pedal is firm. - If the brake pedal feels spongy (soft), repeat the Pressure Bleeding procedure to remove any remaining air from the system. Hydraulic Control Unit (HCU) Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1331 plastic surface, immediately wash the surface with water. NOTE: Pressure bleeding the brake system is preferred to manual bleeding. All vehicles 1. Follow the Pressure Bleeding or Manual Bleeding procedure to bleed the system. 2. Connect the scan tool and follow the ABS Service Bleed instructions. 3. Repeat the Pressure Bleeding or Manual Bleeding procedure to bleed the system. Hybrid vehicles 4. Following the scan tool instructions, carry out the Multi-Calibration Routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering Supplemental Restraint System (SRS) Depowering and Repowering Depowering Procedure WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 OFF. 3. At the Smart Junction Box (SJB), located at the RH side of the center console, remove the cover and the RCM fuse 32 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition from OFF to ON. 2. Install RCM fuse 32 (10A) to the SJB and install the cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1336 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 4. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the 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 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1337 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 to OFF. 3. At the Smart Junction Box (SJB) located at the RH side of the center console, remove the cover and the RCM fuse 32 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Using a 3-mm Allen wrench or a suitable tool, place it in the driver air bag module release hole on the underside of the steering wheel. 8. NOTICE: During driver air bag module removal, make sure all 3 driver air bag module hooks are released from the steering wheel wire Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1338 clip. Failure to do so may cause damage to the driver air bag module and or the steering wheel. NOTE: The driver air bag module is removed for clarity. Position the 3-mm Allen wrench or suitable tool against the wire clip and push inward disengaging the wire clip from the 3 driver air bag module hooks. 9. Disconnect the horn electrical connector. Then disconnect the 2 driver air bag module electrical connectors and remove the driver air bag module. 10. Open and lower the glove compartment door. 11. Remove the 2 passenger air bag module bolts. 12. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Failure to follow this instruction may result in vehicle damage, equipment damage, component damage and/or system failure. NOTE: Use care when removing the passenger air bag module from the instrument panel. The passenger air bag module can drop down during removal and the passenger air bag module rear bracket can scratch the front of the instrument panel. Through the glove compartment opening, release the passenger air bag module deployment door clips while pushing the passenger air bag module out of the instrument panel. 13. Remove the passenger air bag module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1339 1. Disconnect the 2 passenger air bag module electrical connectors. 2. Detach the wire harness routing clip and remove the passenger air bag module. 14. From under the rear of the passenger seat, slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 15. Remove the passenger side D-pillar trim panel. 1. Separate the weatherstrip. 2. Pull out and separate the quarter trim panel at the D-pillar trim panel. 3. Pull out to release the retainers and remove the D-pillar trim panel. 16. Disconnect the passenger side safety canopy module electrical connector. 17. Remove the driver side D-pillar trim panel. 1. Separate the weatherstrip. 2. Pull out and separate the quarter trim panel at the D-pillar trim panel. 3. Pull out to release the retainers and remove the D-pillar trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1340 18. Disconnect the driver side safety canopy module electrical connector. 19. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 20. Install RCM fuse 32 (10A) to the SJB. 21. Connect the battery ground cable. Reactivation 1. Remove RCM fuse 32 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 4. Connect the driver side safety canopy module electrical connector. 5. Install the driver side D-pillar trim panel. 1. Engage the D-pillar trim panel to the quarter trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1341 2. Install the D-pillar trim panel. 3. Install the weatherstrip. 6. Connect the passenger side safety canopy module electrical connector. 7. Install the passenger side D-pillar trim panel. 1. Engage the D-pillar trim panel to the quarter trim panel. 2. Install the D-pillar trim panel. 3. Install the weatherstrip. 8. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 9. NOTICE: During passenger air bag module installation, make sure the passenger air bag module wire harness routing clip is attached to the passenger air bag module. Failure to follow this instruction may result in wiring harness damage. NOTICE: The passenger air bag module electrical connectors are unique and cannot be reversed when connected to the passenger air bag module. Match the electrical connector key to the keyway in the passenger air bag module. Do not force the electrical connectors into the passenger air bag module. Failure to follow these instructions may result in component and/or connector damage. Install the passenger air bag module. 1. Connect the 2 passenger air bag module electrical connectors. 2. Attach the wire harness routing clip. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1342 10. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Failure to follow this instruction may result in vehicle damage, equipment damage, component damage and/or system failure. NOTE: During passenger air bag module installation, make sure all the deployment door clips are fully seated into the instrument panel. NOTE: Use care when installing the passenger air bag module in the instrument panel. The passenger air bag module rear bracket can scratch the front of the instrument panel. Position the passenger air bag module and seat the passenger air bag module deployment door clips into the instrument panel. 11. Install the 2 passenger air bag module bolts. - To install, tighten to 8 Nm (71 lb-in). 12. Close the glove compartment door. 13. Install the driver air bag module electrical connectors fully into the driver air bag module. Then connect the horn electrical connector. 14. NOTE: Make sure the driver air bag module wiring harness is routed down and away from the driver air bag module hooks during installation. NOTE: Audible clicks will be heard when the 3 wire clips are seated in the 3 driver air bag module hooks. Align the driver air bag module hooks to the steering wheel and, while pushing inward, seat the 3 driver air bag module hooks to the steering wheel wire clip. - When the 3 driver air bag module hooks are seated in place, gently pull outward at the corners of the driver air bag module to make sure that the 3 hooks are fully seated. There should also be an even gap between the driver air bag module trim cover and the steering wheel. Check the driver air bag module and trim cover for correct movement when applying the horn. 15. Turn the ignition switch from OFF to ON. 16. Install RCM fuse 32 (10A) to the SJB and install the cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1343 17. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 18. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel Fuse: Locations Passenger Compartment Fuse Panel Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 1349 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 1350 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 1351 Fuse: Locations Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 1352 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 1353 Fuse: Locations Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 1354 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 1355 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 1356 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 1357 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 1358 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 1359 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 1360 Fuse: Locations Power Distribution Box Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 1361 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel Fuse: Application and ID Passenger Compartment Fuse Panel Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1364 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1365 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1366 Fuse: Application and ID Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1367 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1368 Fuse: Application and ID Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1369 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1370 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1371 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1372 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1373 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1374 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1375 Fuse: Application and ID Power Distribution Box Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1376 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1381 Fuse Block: Locations Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1382 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1383 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1386 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1387 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1388 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1389 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1390 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1391 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1392 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1393 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1394 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1395 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1396 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1397 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1398 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1399 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1400 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1401 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1402 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1403 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1404 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1405 Fuse Block: Connector Views Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1406 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1407 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1408 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1409 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1410 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1411 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 1416 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 1417 Relay Box: Locations Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 1418 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 1419 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1422 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1423 Relay Box: Diagrams Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1424 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1425 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1426 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1427 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1428 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) Relay Box: Application and ID Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 1431 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 1432 Relay Box: Application and ID Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 1433 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) The MIL alerts the driver that the powertrain control module (PCM) has detected an on board diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD diagnostic trouble code (DTC) is set. - The MIL is located on the instrument cluster and is labeled as International Standards Organization (ISO) engine symbol. - Power is supplied to the MIL whenever the key is in the ON or START position. - The MIL remains on in the on/start mode as a bulb check during the instrument cluster prove-out 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 is set. - the instrument cluster illuminates 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). - If the MIL remains off during the bulb check, there is: an instrument cluster concern. - an instrument cluster wiring concern. - 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 concern. - For any MIL concern, refer to Symptom Charts, GO to Quick Test QT1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/QT : Powertrain Control Module (PCM)/Transaxle Control Module (TCM) Quick Test . - If the MIL blinks at a steady rate, a severe misfire condition may exist. - The MIL flashes after a period of time with the key in the RUN position (engine not running) if DTC P1000 is set. ISO Standard Engine Symbol Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair To reset the oil monitoring system to 100% after each oil change (approximately 10,000 miles [16,000 km] or 12 months) perform the following. 1. Press the SETUP control to display "OIL LIFE= XXX% HOLD RESET=NEW". 2. Press and hold the RESET control for 2 seconds and release. Oil life is set to 100% and "OIL LIFE SET TO 100%" is displayed. 3. While "OIL LIFE SET TO 100%" is displayed, if a lower oil life start value is desired, press and release the RESET control to reduce the start value. Each press of the RESET control reduces the start value by 10 percent. NOTE: Oil life start value of 100% equals 10,000 miles [16,000 km] or 12 months. For example, setting oil life start value to 60% sets the oil life start value to 6,000 miles [9,600 km] and 219 days. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation Jacking and Lifting WARNING: When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle movement. Failure to follow these instructions may result in serious personal injury. WARNING: Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions may result in serious personal injury. WARNING: Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure to follow this instruction may result in serious personal injury. WARNING: Vehicle may have multiple drive wheels. Do not use engine to power the driveline unless all drive wheels are elevated off the ground. Drive wheels in contact with ground could cause unexpected vehicle movement. Failure to follow this instruction may result in serious personal injury. WARNING: Position the hoist lift arms as shown in the illustration. Incorrect positioning could result in vehicle slipping or falling from the hoist. Failure to follow this instruction may result in serious personal injury. NOTICE: The jack provided with the vehicle is intended to be used in an emergency for changing a deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other purpose. NOTICE: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on lift without first checking for possible interference. NOTICE: Damage to the rear tire air deflector, suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Front and Rear - Jacking and Lifting Points Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Tire Monitoring System/Testing and Inspection/Programming and Relearning. NOTE: The Tire Pressure Monitoring System (TPMS) Training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. NOTE: Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place at the valve stem. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall at the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall at the valve stem and press and release the test button to train the RF tire pressure sensor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1450 8. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1451 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" when a vehicle is stationary to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall at the tire valve stem. 3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. This feedback may not always be present, do not rely on it to reflect the most recent pressure data. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. If the sensor still does not respond, attempt to activate the same sensor again using the customer activation tool (if available). If the sensor still fails to train, attempt to train the sensor with the vehicle doors open. Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor. Activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Testing and Inspection/Programming and Relearning. NOTE: The Tire Pressure Monitoring System (TPMS) Training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. NOTE: Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place at the valve stem. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall at the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall at the valve stem and press and release the test button to train the RF tire pressure sensor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1457 8. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1458 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" when a vehicle is stationary to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall at the tire valve stem. 3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. This feedback may not always be present, do not rely on it to reflect the most recent pressure data. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. If the sensor still does not respond, attempt to activate the same sensor again using the customer activation tool (if available). If the sensor still fails to train, attempt to train the sensor with the vehicle doors open. Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor. Activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Wheel Bearing and Wheel Hub Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. NOTE: If removing the wheel hub, a new wheel bearing must be installed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1463 1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair. 2. Using the Pinion Bearing Cone Remover, press the wheel hub from the wheel bearing. 3. 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 Pinion Bearing Cone Remover, press the inner wheel bearing race from the wheel hub. 4. Remove the snap ring. 5. Using the Pinion Bearing Cone Remover, Wheel Bearing Adapter and Handle, press the outer wheel bearing race from the wheel knuckle. Installation 1. Position the wheel knuckle in a vise. 2. NOTE: Step Plate 205-278 is not seen in place. It is located behind the wheel knuckle. Using the Pinion Bearing Cup Replacer and the 2 Step Plates, install the wheel bearing into the wheel knuckle. 3. Install the snap ring. 4. Using the Pinion Bearing Cone Remover, press the wheel hub into the wheel bearing. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1464 5. Install the wheel knuckle. For additional information, refer to Wheel Knuckle See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1465 Wheel Bearing: Service and Repair Rear Suspension Wheel Bearing - All Wheel Drive (AWD) Removal Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1466 1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle - All Wheel Drive (AWD) See: Steering and Suspension/Suspension/Rear Knuckle/Service and Repair. 2. Remove the wheel bearing snap ring. 3. Remove the 4 bolts and the brake drum backing plate. 4. Position the wheel knuckle on a suitable press. - Using the PTO Driven Gear Oil Seal Installer, the Handle and the Pinion Bearing Cone Remover or equivalent, position the wheel knuckle on a suitable press and press the wheel bearing from the wheel knuckle. Installation 1. Using the Rear Axle Drawbar, Bearing Cup Replacer and Differential Bearing Cup Replacer, install a new wheel bearing into the wheel knuckle. 2. Install the new wheel bearing snap ring. 3. Install the 4 bolts and the brake drum backing plate. - Tighten to 85 Nm (63 lb-ft). 4. Using the Halfshaft Installer and Receiver Adapter, install the wheel hub into the wheel bearing. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1467 5. Install the wheel knuckle. For additional information, refer to Wheel Knuckle - All Wheel Drive (AWD) See: Steering and Suspension/Suspension/Rear Knuckle/Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Rear Install the new wheel hub nut Tighten to..................................................................................... ..............................................................................................................290 Nm (214 lb-ft). Front Install the new wheel hub nut Tighten to..................................................................................... ..............................................................................................................300 Nm (221 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Install the 5 wheel nuts. Tighten the wheel nuts in a star pattern. Tighten to....................................... ............................................................................................................................................................1 35 Nm (100 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. 1. Remove the wheel bearing and hub. For additional information, refer to Wheel Bearing and Wheel Hub See: Wheel Bearing/Service and Repair/Front Suspension. 2. Using a suitable press, remove the wheel stud from the wheel hub. - Discard the wheel stud. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 1477 Wheel Fastener: Service and Repair Rear Suspension Wheel Studs Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. NOTICE: Never use a hammer to remove a wheel stud. Damage to the wheel hub may result. 1. Remove the brake shoes. 2. Using the C-Frame and Screw Installer/Remover, remove the wheel stud. 3. NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud serrations. Use enough washers (approximately 4) to allow the wheel stud to fully seat against the hub flange. Position the new wheel stud in the wheel hub, aligning the serrations in the wheel hub flange made by the original wheel stud. - Place approximately 4 washers over the outside end of the wheel stud and thread a standard wheel nut onto the wheel stud with the flat side Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 1478 against the washers. - Tighten the wheel nut until the wheel stud head seats against the back side of the wheel hub flange. 4. Remove the wheel nut and washers. 5. Install the brake shoes. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > A/T Vehicle Flat Towing Guidelines Towing Information: Technical Service Bulletins A/T - Vehicle Flat Towing Guidelines TSB 09-20-13 10/19/09 6F35 TRANSMISSION - RECREATIONAL TOWING - VEHICLE WITH ALL 4 WHEELS ON THE GROUND - EXPANDED GUIDELINES TO PREVENT TRANSMISSION DAMAGE FORD: 2010 Fusion 2009-2010 Escape MERCURY: 2010 Milan 2009-2010 Mariner ISSUE Some 2009-2010 Escape, Mariner, 2010 Fusion and Milan vehicles equipped with a 6F35 automatic transmission, may experience transmission shift concerns after towing the vehicle with all 4 wheels on the ground (Flat tow) such as behind a motor home or a truck. The transmission shift concern may be caused by heat build up in the transmission due to the transmission fluid level being too high, towing speeds above 65 MPH (105 Km/h) and/or not stopping to run the engine at idle for 5 minutes every six hours or less, to cool the transmission. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE There are specific instructions listed in the Owner Guide that must be followed to recreational tow/flat tow/tow a vehicle with all 4 tires on the ground. Advise customers of the following expanded recreational towing guidelines. 1. Transmission fluid level must be checked at operating temperature of 185 °F - 200 °F (85 °C - 93 °C), per Workshop Manual (WSM), Section 307-01. At this temperature, adjust fluid level between minimum line and the minimum hole at the bottom of the hash marks on dipstick. This level is within the safe operating fluid level and does not require the customer to have the fluid level readjusted after flat tow operation. (Figure 1) 2. Maximum towing speed is 65 MPH (105 Km/h). 3. Do not flat tow the vehicle for greater than 6 hours at a time. 4. Start and run the engine for: a. 5 minutes before towing each day b. 5 minutes every 6 hours or less. c. While running the engine at idle for 5 minutes, with foot on the brake, shift through all gears. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > A/T Vehicle Flat Towing Guidelines > Page 1483 These guidelines are designed to prevent damage to the transmission due to overheating. If setting the fluid level for a customer that will be recreational (flat) towing the vehicle, set the level between minimum line and the minimum hole at the bottom of the hash marks on dipstick (Figure 1) per WSM Section 307-01. NOTE THERE IS A SIGNIFICANT DIFFERENCE IN TRANSMISSION DIPSTICK READINGS BETWEEN A COLD TRANSMISSION AND A TRANSMISSION AT OPERATING TEMPERATURE. FAILURE TO CHECK TRANS FLUID LEVEL AT TRANS OPERATING TEMPERATURE, PER WSM SECTION 307-01 MAY RESULT IN DAMAGE TO THE TRANSMISSION. If the vehicle is a 2009 Escape or Mariner and built on or before 10/28/2008 the dipstick does not have Minimum - Maximum lines outside of hash marks, then replace dipstick. 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 MT092013 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 7000 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation Jacking and Lifting WARNING: When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle movement. Failure to follow these instructions may result in serious personal injury. WARNING: Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions may result in serious personal injury. WARNING: Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure to follow this instruction may result in serious personal injury. WARNING: Vehicle may have multiple drive wheels. Do not use engine to power the driveline unless all drive wheels are elevated off the ground. Drive wheels in contact with ground could cause unexpected vehicle movement. Failure to follow this instruction may result in serious personal injury. WARNING: Position the hoist lift arms as shown in the illustration. Incorrect positioning could result in vehicle slipping or falling from the hoist. Failure to follow this instruction may result in serious personal injury. NOTICE: The jack provided with the vehicle is intended to be used in an emergency for changing a deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other purpose. NOTICE: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on lift without first checking for possible interference. NOTICE: Damage to the rear tire air deflector, suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Front and Rear - Jacking and Lifting Points Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1493 Variable Valve Timing Actuator: Description and Operation Variable Camshaft Timing (VCT) System Overview The intake phase shifting (IPS) VCT system enables rotation of the intake camshaft relative to the crankshaft rotation as a function of engine operating conditions. The VCT system has several operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on a constant angle, limited by engine oil temperature and engine RPM. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. Variable Camshaft Timing (VCT) System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel indicates the CMP signal for that bank. A crankshaft position (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT), cylinder head temperature (CHT), CMP, accelerator pedal position (APP) sensor (via requested torque), mass air flow (MAF), and CKP sensors to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on engine oil temperature and engine speed inputs. During cold start emissions reduction mode, the camshaft position is determined via engine speed and estimates of engine coolant temperature and catalyst temperature (estimated from other sensors already used such as IAT/CHT/MAF/CKP). During part and wide open throttle, the camshaft position is determined by engine RPM, load and accelerator pedal position. The VCT system does not operate until the engine is at normal operating oil temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a default position if a concern is detected. A related diagnostic trouble code (DTC) is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the two halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. VCT System Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair Variable Valve Timing Solenoid: Service and Repair Variable Camshaft Timing (VCT) Oil Control Solenoid Removal and Installation 1. Remove the valve cover. 2. Remove the bolt and the Variable Camshaft Timing (VCT) oil control solenoid. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil meeting Ford specification on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are worn or damaged. 2. If compression does not improve, valves are sticking or not seating correctly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so the lowest reading is within 75% of the highest reading. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1500 Compression Check: Testing and Inspection Engine Component Tests The following component tests are used to diagnose engine concerns. Compression Test - Hybrid The compression test requires cranking the engine a minimum of 5 compression strokes with the throttle plate in the wide-open position for each cylinder. The engine cranking diagnostic mode must be used to crank the engine and the brake/accelerator pedals must be used to position the throttle plate during the compression test. The engine cranking diagnostic mode is a PCM strategy which is separate from the normal operating strategy. It allows the engine to crank in a similar fashion as a conventional vehicle with the fuel disabled. When in this mode, the PCM commands the Transmission Control Module (TCM) to spin the generator, which cranks the engine with the speed between 900 and 1,200 rpm. The engine will crank as long as the traction battery state of charge stays greater than 35%. 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level. Operate the vehicle until the engine is at normal operating temperature. 2. Using the Vehicle Communication Module (VCM), access the Battery Control Module (BCM) and monitor the traction battery state of charge PID. If the monitored PID displays the state of charge below 45%, start and idle the engine with full A/C ON. When the traction battery state of charge exceeds 45%, the engine cranking diagnostic mode can be activated. 3. Turn the ignition switch to the OFF position, then remove all the spark plugs. 4. Install a compression gauge in the No. 1 cylinder. 5. Activate the cranking diagnostic mode as follows: - Apply the parking brake. - Place the gear selector in the PARK position. - Verify the key is in the OFF position. - NOTE: Do not crank the engine. Turn the key to the ON position with the engine OFF. - Within 5 seconds of the key in the ON position, fully apply the accelerator pedal and hold for 10 seconds. - Within 5 seconds release the accelerator pedal, shift the gear selector to the NEUTRAL position and fully apply the accelerator pedal. - Hold the accelerator pedal fully applied for 10 seconds. - Release the accelerator pedal and shift the gear selector to the PARK position. If the sequence is correctly executed, the instrument cluster hazard indicator (red triangle) flashes once per second when the gear selector is shifted to the PARK position. The PCM exits the engine cranking diagnostic mode when the traction battery state of charge drops below 35%, the gear selector is shifted to any gear other than PARK or when the ignition key is turned to the OFF or ACC position. 6. NOTE: If the ignition key stays in the START position for 15 seconds or longer, the PCM may set DTC P2535. NOTE: If the brake pedal is not depressed and held prior to depressing the accelerator pedal, the throttle plate will fail to open. Crank the engine as follows: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1501 - Depress and hold the brake pedal. - Fully depress and hold the accelerator pedal. - Turn the key to the START position and crank the engine a minimum of 5 compression strokes and record the highest reading. Return the key to the ON position. - Release the accelerator pedal. - Release the brake pedal. 7. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 8. Position the key to the OFF position to deactivate the cranking diagnostic mode. 9. Clear all DTCs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages: Stage 1: Tighten 1 turn at a time until tight. Stage 2: Tighten to.............................................................................................................................................. ............................................7 Nm (62 lb-in). Stage 3: Tighten to......................................................... .............................................................................................................................16 Nm (142 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft sprocket bolts....................................................................................................................... ...........................................................72 Nm (53 lb-ft) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures Camshaft: Procedures Camshaft Journal To Bearing Clearance - OHC Engines Camshaft Journal to Bearing Clearance - OHC Engines NOTE: Refer to the Engine System Level for the specification. 1. NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. Measure each camshaft bearing in 2 directions. - Subtract the camshaft journal diameter from the camshaft bearing diameter. Camshaft End Play - OHC Engines Camshaft End Play - OHC Engines NOTE: Refer to the Engine System Level for the specification. 1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play. 2. Position the camshaft to the rear of the cylinder head. 3. Zero the Dial Indicator Gauge. 4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. - If camshaft end play exceeds specifications, install a new camshaft and recheck end play. - If camshaft end play exceeds specification after camshaft installation, install a new cylinder head. Camshaft Surface Inspection Camshaft Surface Inspection 1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside the contact area. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1513 Camshaft Bearing Journal Diameter Camshaft Bearing Journal Diameter NOTE: Refer to the Engine System Level for the specification. 1. Measure each camshaft journal diameter in 2 directions. Camshaft Lobe Lift Camshaft Lobe Lift NOTE: Refer to the Engine System Level for the specification. 1. Use the Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift. - Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial Indicator Gauge reading to figure the camshaft lobe lift. Camshaft Runout Camshaft Runout Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1514 NOTE: Refer to the Engine System Level for the specification. 1. NOTE: Camshaft journals must be within specifications before checking runout. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft runout. - Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial Indicator Gauge reading. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1515 Camshaft: Removal and Replacement Camshaft Phaser and Sprocket Camshaft Phaser and Sprocket Removal NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. NOTICE: Do not rotate the camshafts or crankshaft unless instructed to do so in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves or pistons. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Remove the Variable Camshaft Timing (VCT) solenoid. 4. Check the valve clearance. For additional information, refer to Valve Clearance Check See: Adjustments. 5. NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). - The hole in the crankshaft pulley should be in the 6 o'clock position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1516 6. NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts. 7. Remove the engine plug bolt. 8. NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the camshaft removal and installation. Install the Crankshaft TDC Timing Peg. 9. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1517 10. Remove the lower timing hole plug from the engine front cover. 11. Remove the upper timing hole plug from the engine front cover. 12. Reposition the Camshaft Alignment Plate to the slot on the rear of the intake camshaft only. 13. NOTE: Releasing the ratcheting mechanism in the timing chain tensioner allows the plunger to collapse and create slack in the timing chain. Installing the M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole will lock the tensioner arm in a retracted position and allow enough slack in the timing chain for removal of the exhaust camshaft gear. Using a small pick tool, release the timing chain tensioner ratchet through the lower front cover timing hole. - Have an assistant rotate (using the flats of the camshaft) the exhaust camshaft clockwise to collapse the timing chain tensioner plunger. - Insert the M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1518 14. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft drive gear. 15. Remove the Camshaft Alignment Plate. 16. Remove the timing chain from the camshaft phaser and sprocket. 17. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1519 18. NOTICE: Failure to follow the camshaft loosening procedure can result in damage to the intake camshaft. Remove the intake camshaft from the engine. - Loosen the intake camshaft bearing cap bolts, in the sequence shown, one turn at a time until all tension is released from the camshaft bearing caps. - Remove the bolts and the camshaft bearing caps. - Remove the intake camshaft. 19. Mark the camshaft phaser and sprocket and the camshaft for reference during installation. 20. Place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket. Installation 1. NOTE: If new parts are installed, transfer the reference marks made during disassembly to the new parts. Position the camshaft in a soft-jawed vise. Install the camshaft phaser and sprocket and the bolt. - Align the reference marks on the camshaft phaser and sprocket and the camshaft. Tighten the bolt to 72 Nm (53 lb-ft). 2. NOTICE: Install the intake camshaft with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons. NOTE: Lubricate the intake camshaft journals and bearing caps with clean engine oil. Install the intake camshafts and bearing caps. Tighten the intake camshaft bearing caps in the sequence shown in 3 stages: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1520 - Stage 1: Tighten the intake camshaft bearing cap bolts until finger tight. - Stage 2: Tighten to 7 Nm (62 lb-in). - Stage 3: Tighten to 16 Nm (142 lb-in). 3. Install the Camshaft Alignment Plate. 4. Install the timing chain on the camshaft phaser and sprocket. 5. NOTE: The timing chain must be correctly engaged on the teeth of the crankshaft timing sprocket and the intake camshaft drive gear in order to install the exhaust camshaft drive gear onto the exhaust camshaft. Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the exhaust camshaft. - Hand-tighten the bolt. 6. NOTE: Releasing the tensioner arm will remove the slack from the timing chain. Remove the M6 x 30 mm (1.18 in) bolt from the upper front cover timing hole to release the tensioner arm. 7. NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Using the flats on the camshaft to prevent camshaft rotation, tighten the exhaust camshaft drive gear bolt to 72 Nm (53 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1521 8. Remove the Camshaft Alignment Plate. 9. Remove the 6 mm x 18 mm bolt. 10. Remove the Crankshaft TDC Timing Peg. 11. Install the upper timing hole plug in the engine front cover. - Tighten to 10 Nm (89 lb-in). 12. Apply silicone gasket and sealant to the threads of the lower timing hole plug. - Install the lower timing hole plug in the engine front cover. Tighten to 12 Nm (106 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1522 13. Install the engine plug bolt. - Tighten to 20 Nm (177 lb-in). 14. Install the accessory drive belt. 15. Install the Variable Camshaft Timing (VCT) solenoid. Valve Train Components - Exploded View Valve Train Components - Exploded View 1. For additional information, refer to the procedures. Camshafts Camshafts Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1523 Removal NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure. NOTICE: Do not rotate the camshafts unless instructed to in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves and pistons. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. NOTICE: Before removing the high voltage cables, the vehicle electrical system must be completely shut down for at least 5 minutes to allow for the high voltage capacitors to discharge. Depower the vehicle High Voltage Traction Battery (HVTB) electrical system. For additional information, refer to Hybrid Drive Systems. 4. Remove the degas bottle. 5. Remove the DC/DC converter. For additional information, refer to Hybrid Drive Systems. 6. Remove the Variable Camshaft Timing (VCT) oil control solenoid. 7. Check the valve clearance. For additional information, refer to Valve Clearance Check See: Adjustments. 8. Remove the RF wheel and tire. 9. Remove the accessory drivebelt. 10. NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). - The hole in the crankshaft pulley should be in the 6 o'clock position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1524 11. NOTICE: The Camshaft Alignment Plate 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts. 12. Remove the engine plug bolt. 13. NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the camshaft removal and installation. Install the Crankshaft TDC Timing Peg and turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg. 14. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1525 15. Remove the lower front cover timing hole plug from the engine front cover. 16. Remove the upper front cover timing hole plug from the engine front cover. 17. Reposition the Camshaft Alignment Plate to the slot on the rear of the intake camshaft only. 18. NOTE: Releasing the ratcheting mechanism in the timing chain tensioner allows the plunger to collapse and create slack in the timing chain. Installing an M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole will hold the tensioner arm in a retracted position and allow enough slack in the timing chain for removal of the exhaust camshaft gear. Using a small pick tool, unlock the chain tensioner ratchet through the lower front cover timing hole. - Using the flats of the camshaft, have an assistant rotate the exhaust camshaft clockwise to collapse the timing chain tensioner plunger. - Insert an M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1526 19. Remove the Camshaft Alignment Plate. 20. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and exhaust camshaft drive gear. 21. Remove the timing chain from the camshaft phaser and sprocket. 22. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1527 23. NOTICE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. NOTE: Mark the location and orientation of each camshaft bearing cap. Remove the camshafts from the engine. - Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is released from the camshaft bearing caps. - Remove the bolts and the camshaft bearing caps. - Remove the camshafts. 24. If removal of the camshaft phaser and sprocket is necessary, mark the sprocket and camshaft for reference during installation. - If necessary, place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket. Installation 1. NOTE: If new parts are installed, transfer the reference marks made during disassembly to the new parts. If necessary, position the camshaft in a soft-jawed vise and install the camshaft phaser and sprocket and the bolt. - Align the reference marks on the camshaft phaser and sprocket and the camshaft. Tighten the bolt to 72 Nm (53 lb-ft). 2. NOTICE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons. NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1528 - Stage 1: Tighten the camshaft bearing cap bolts one turn at a time, until finger tight. - Stage 2: Tighten to 7 Nm (62 lb-in). - Stage 3: Tighten to 16 Nm (142 lb-in). 3. Install the Camshaft Alignment Plate. 4. Install the timing chain on the camshaft phaser and sprocket. 5. NOTE: The timing chain must be correctly engaged on the teeth of the crankshaft timing sprocket and the intake camshaft drive gear in order to install the exhaust camshaft drive gear onto the exhaust camshaft. Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the exhaust camshaft. - Hand-tighten the bolt. 6. NOTE: Releasing the tensioner arm will remove the slack from the timing chain release. Remove the M6 x 30 mm bolt from the upper front cover timing hole to release the tensioner arm. 7. NOTICE: The Camshaft Alignment Plate 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Using the flats on the camshaft to prevent camshaft rotation, tighten the bolt. - Tighten to 72 Nm (53 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1529 8. Remove the Camshaft Alignment Plate. 9. Remove the 6 mm x 18 mm bolt. 10. Remove the Crankshaft TDC Timing Peg. 11. Install the upper front cover timing hole plug. - Tighten to 10 Nm (89 lb-in). 12. Apply silicone gasket and sealant to the threads of the lower front cover timing hole plug. - Install the plug and tighten to 12 Nm (106 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1530 13. Install the engine plug bolt. - Tighten to 20 Nm (177 lb-in). 14. Install the accessory drivebelt. 15. Install the RF wheel and tire. 16. Install the VCT oil control solenoid. 17. Install the valve cover. For additional information, refer to Valve Cover See: Service and Repair/Removal and Replacement/Valve Cover. 18. Install the DC/DC converter. For additional information, refer to Hybrid Drive Systems. 19. Install the degas bottle. 20. Repower the vehicle HVTB electrical system. For additional information, refer to Hybrid Drive Systems. 21. Connect the battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures Lifter / Lash Adjuster: Procedures Valve Tappet Inspection Valve Tappet Inspection 1. Inspect the valve tappet for damage, especially in the indicated areas. If any damage is evident, inspect the camshaft lobes and valves for damage. Install new components as necessary. Hydraulic Lash Adjuster Inspection Hydraulic Lash Adjuster Inspection 1. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 1535 Lifter / Lash Adjuster: Removal and Replacement Valve Tappets Valve Tappets Removal and Installation NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the camshafts. For additional information, refer to Camshafts See: Camshaft/Service and Repair/Removal and Replacement/Camshafts. 3. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. Remove and inspect the valve tappets. 4. To install, reverse the removal procedure. - Coat the valve tappets with clean engine oil prior to installation. Valve Train Components - Exploded View Valve Train Components - Exploded View Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 1536 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures Rocker Arm Assembly: Procedures Roller Follower Inspection 1. Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft lobes and hydraulic lash adjuster for damage. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1541 Rocker Arm Assembly: Removal and Replacement Valve Train Components - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1545 Variable Valve Timing Actuator: Description and Operation Variable Camshaft Timing (VCT) System Overview The intake phase shifting (IPS) VCT system enables rotation of the intake camshaft relative to the crankshaft rotation as a function of engine operating conditions. The VCT system has several operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on a constant angle, limited by engine oil temperature and engine RPM. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. Variable Camshaft Timing (VCT) System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel indicates the CMP signal for that bank. A crankshaft position (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT), cylinder head temperature (CHT), CMP, accelerator pedal position (APP) sensor (via requested torque), mass air flow (MAF), and CKP sensors to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on engine oil temperature and engine speed inputs. During cold start emissions reduction mode, the camshaft position is determined via engine speed and estimates of engine coolant temperature and catalyst temperature (estimated from other sensors already used such as IAT/CHT/MAF/CKP). During part and wide open throttle, the camshaft position is determined by engine RPM, load and accelerator pedal position. The VCT system does not operate until the engine is at normal operating oil temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a default position if a concern is detected. A related diagnostic trouble code (DTC) is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the two halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. VCT System Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1550 a No. 3 Journal - Supported by No. 1 and No. 5 journals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1554 a No. 3 Journal - Supported by No. 1 and No. 5 journals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1558 a No. 3 Journal - Supported by No. 1 and No. 5 journals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1562 a No. 3 Journal - Supported by No. 1 and No. 5 journals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1563 Crankshaft: Service and Repair Crankshaft End Play NOTE: Refer to the Engine System Level for the specification. 1. Install the Dial Indicator Gauge with Holding Fixture. 2. Position the crankshaft to the rear of the cylinder block. 3. Zero the Dial Indicator Gauge. 4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 2.5L 3.0L Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Cooling System/Service and Repair. 3. NOTICE: Make sure that the block heater wiring is routed and secured away from rotating or hot components, or damage to the wiring can occur. Disconnect the block heater electrical connector. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Page 1567 4. Remove the block heater. - To install, tighten to 20 Nm (177 lb-in) (2.5L). - To install, tighten to 25 Nm (18 lb-ft) (3.0L). 5. To install, reverse the removal procedure. 6. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Cooling System/Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to...................................................... .................................................................................................................................100 Nm (74 lb-ft). Stage 2: Tighten an additional.............................................................................................................. .......................................90 degrees (one-fourth turn). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Crankshaft Pulley Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley Crankshaft Pulley Removal NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur. NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the RF wheel and tire. 3. Remove the accessory drive belt. 4. Remove the valve cover. For additional information, refer to Valve Cover See: Service and Repair/Removal and Replacement/Valve Cover. 5. NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). - The hole in the crankshaft pulley should be in the 6 o'clock position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Crankshaft Pulley > Page 1573 6. NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts. 7. Remove the engine plug bolt. 8. NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation. Install the Crankshaft TDC Timing Peg. 9. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool, and the bolt should be removed using an air impact wrench (1/2-in drive minimum). NOTICE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced. Remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Crankshaft Pulley > Page 1574 Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt. - Remove and discard the crankshaft pulley bolt and washer. - Remove the crankshaft pulley. - Remove the diamond washer and discard. Installation 1. Install a new diamond washer. 2. NOTE: Do not install the crankshaft pulley bolt at this time. NOTE: Apply clean engine oil on the seal area before installing. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position. 3. NOTICE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur. NOTE: This step will correctly align the crankshaft pulley to the crankshaft. Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover. 4. NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only. NOTE: Do not reuse the crankshaft pulley bolt. Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). - Stage 2: Tighten an additional 90 degrees. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Crankshaft Pulley > Page 1575 5. Remove the 6 mm x 18 mm bolt. 6. Remove the Crankshaft TDC Timing Peg. 7. Remove the Camshaft Alignment Plate. 8. NOTE: Only turn the engine in the normal direction of rotation. Turn the crankshaft clockwise one and three-fourths turns. 9. Install the Crankshaft TDC Timing Peg. 10. NOTE: Only turn the engine in the normal direction of rotation. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Crankshaft Pulley > Page 1576 11. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley. - If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this procedure. 12. Install the Camshaft Alignment Plate to check the position of the camshafts. - If it is not possible to install the special tool, the engine valve timing must be corrected by repeating this procedure. 13. Remove the Camshaft Alignment Plate. 14. Remove the 6 mm x 18 mm bolt. 15. Remove the Crankshaft TDC Timing Peg. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Crankshaft Pulley > Page 1577 16. Install the engine plug bolt. - Tighten to 20 Nm (177 lb-in). 17. Install the accessory drive belt. 18. Install the RF wheel and tire. 19. Install the valve cover. For additional information, refer to Valve Cover See: Service and Repair/Removal and Replacement/Valve Cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Crankshaft Pulley > Page 1578 Harmonic Balancer - Crankshaft Pulley: Service and Repair Exploded View - Crankshaft Pulley and Crankshaft Front Oil Seal Lower End Components - Exploded View Crankshaft Pulley and Crankshaft Front Oil Seal Flywheel and Crankshaft Rear Oil Seal Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Crankshaft Pulley > Page 1579 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1583 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1584 a No. 3 Journal - Supported by No. 1 and No. 5 journals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1588 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1589 a No. 3 Journal - Supported by No. 1 and No. 5 journals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications NOTE: The nominal clearance is: intake:............................................................................................. .........................................................................................................0.25 mm (0.0095 in). exhaust:..... .............................................................................................................................................................. .................................0.30 mm (0.0115 in). The acceptable clearances after being fully installed are: intake:........................................................ .............................................................................................................................0.22-0.28 mm (0.008-0.011 in). exhaust:..................................................................................................................... ..............................................................0.27-0.33 mm (0.010-0.013 in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1594 Valve Clearance: Adjustments Valve Clearance Check 1. Remove the valve cover. For additional information, refer to Valve Cover See: Service and Repair/Removal and Replacement/Valve Cover. 2. Remove the 5 bolts, the pin-type retainer (not shown) and the RH splash shield. - To install, tighten to 9 Nm (80 lb-in). 3. NOTE: Turn the engine clockwise only, and only use the crankshaft bolt. NOTE: Before removing the camshafts, measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure the clearance of each valve and record its location. 4. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: The nominal clearance is: intake: 0.25 mm (0.0095 in). - exhaust: 0.30 mm (0.0115 in). The acceptable clearances after being fully installed are: - intake: 0.22-0.28 mm (0.008-0.011 in). - exhaust: 0.27-0.33 mm (0.010-0.013 in). Select tappets using this formula: tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. Select the closest tappet size to the ideal tappet thickness available and mark the installation location. 5. If any tappets do not measure within specifications, install new tappets in these locations. For additional information, refer to Valve Train Components - Exploded View See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Valve Train Components - Exploded View and Valve Tappets See: Camshaft, Lifters and Push Rods/Lifter / Lash Adjuster/Service and Repair/Removal and Replacement/Valve Tappets. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel System Pressure Release WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. NOTE: The Fuel Pump (FP) fuse is located in the Battery Junction Box (BJB), location 22. Remove the FP fuse. 2. Start the engine and allow it to idle until it stalls. 3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released. 4. Turn the ignition switch to the OFF position. 5. When the fuel system service is complete, install the FP fuse. 6. NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for leaks prior to starting the engine. Start the vehicle and check the fuel system for leaks. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures Rocker Arm Assembly: Procedures Roller Follower Inspection 1. Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft lobes and hydraulic lash adjuster for damage. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1602 Rocker Arm Assembly: Removal and Replacement Valve Train Components - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair Valve Cover: Service and Repair Valve Cover Valve Cover (View 1 of 2) Valve Cover (View 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 1606 Removal NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the ignition coil-on-plugs. 3. Disconnect the crankcase vent hose from the valve cover. 4. Remove the 4 engine cover studs. 5. Detach the 3 wire harness retainers from the valve cover stud bolts. 6. Disconnect the Camshaft Position (CMP) sensor electrical connector. 7. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 8. Disconnect the Variable Camshaft Timing (VCT) solenoid electrical connector. 9. Remove the oil level indicator. 10. Remove the 14 valve cover retainers, the valve cover and gasket. Installation 1. NOTICE: 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. Clean and inspect the sealing surfaces. 2. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. Apply silicone gasket and sealant to the locations shown. 3. NOTE: Clean and inspect the gasket. Install a new gasket, if necessary. Install the valve cover, gasket and retainers. - Tighten in the sequence shown to 10 Nm (89 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 1607 4. Install the oil level indicator. 5. Connect the VCT solenoid electrical connector. 6. Connect the CHT sensor electrical connector. 7. Connect the CMP sensor electrical connector. 8. Attach the 3 wire harness retainers to the valve cover stud bolts. 9. Install the 4 engine cover studs. 10. Connect the crankcase vent hose to the valve cover. 11. Install the ignition coil-on-plugs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Service and Repair Valve Guide: Service and Repair Valve Guide Inner Diameter NOTE: Refer to the Engine System Level for the specification. 1. NOTE: Valve guides tend to wear in an hourglass pattern. The ball gauge can be inserted into the combustion chamber side of the valve guide, if necessary. Use a ball gauge to determine the inside diameter of the valve guides in 2 directions at the top, middle and bottom of the valve guide. 2. Measure the ball gauge with a micrometer. 3. If the valve guide is not within specifications, install a new cylinder head assembly. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Service and Repair > Valve and Seat Refacing Measurements Valve Seat: Service and Repair Valve and Seat Refacing Measurements Valve Seat Inspection Valve and Seat Refacing Measurements NOTE: Refer to the Engine System Level for the specification. NOTE: After grinding valves or valve seats, check valve clearance. 1. Check the valve head and seat. - Check valve angles. - Check margin width. - Be sure margin width is within specification. 2. Inspect for abnormalities on the valve face and seat. Install a new cylinder head assembly if abnormalities are found. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Service and Repair > Valve and Seat Refacing Measurements > Page 1615 Valve Seat: Service and Repair Valve Seat Width Valve Seat Width NOTE: Refer to the Engine System Level for the specification. 1. Measure the valve seat width. If necessary, grind the valve seat to specification. - Measure the intake valve seat width. - Measure the exhaust valve seat width. - Recheck the valve spring installed length after the seats have been ground, and shim the valve springs as necessary to achieve the correct installed spring length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Service and Repair > Valve and Seat Refacing Measurements > Page 1616 Valve Seat: Service and Repair Valve Seat Runout Valve Seat Runout NOTE: Refer to the Engine System Level for the specification. 1. Use a valve seat runout gauge to check valve seat runout. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures Valve Spring: Procedures Valve Spring Installed Length Valve Spring Installed Length NOTE: Refer to the Engine System Level for the specification. 1. Measure the installed length of each valve spring. Valve Spring Free Length Valve Spring Free Length NOTE: Refer to the Engine System Level for the specification. 1. Measure the free length of each valve spring. Valve Spring Squareness Valve Spring Squareness 1. Measure the out-of-square on each valve spring. - Turn the valve spring and observe the space between the top of the valve spring and the square. Valve Spring Strength Valve Spring Strength Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1621 NOTE: Refer to the Engine System Level for the specification. 1. Use the Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the specified valve spring length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1622 Valve Spring: Removal and Replacement Valve Train Components - Exploded View Valve Train Components - Exploded View 1. For additional information, refer to the procedures. Valve Springs Valve Springs Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1623 Removal NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the camshafts. For additional information, refer to Camshafts See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshafts. 3. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. Remove and inspect the valve tappets. 4. Remove the spark plugs. 5. NOTICE: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect the compressed air from the cylinder until the valve spring, valve spring retainer and valve collet is installed. Any loss of air pressure will allow the valve to fall into the cylinder. Connect the compressed air supply to the No. 1 cylinder. 6. NOTE: Place all parts in order to one side. Apply compressed air to the cylinder and remove the valve spring. - Using the Valve Spring Compressors, compress the valve spring and remove the valve collet, using some grease and a small screwdriver. - Remove the valve spring retainer and the valve spring. Installation 1. NOTE: Check the seating of the valve collet. Using the Valve Spring Compressors, install the valve spring. - Insert the valve spring and the valve spring retainer. - Compress the valve spring and install the valve collet using some grease and a small screwdriver. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1624 2. Disconnect the compressed air supply. 3. Repeat the appropriate removal and installation steps for all of the other cylinders. 4. Install the spark plugs. 5. Coat the valve tappets with clean engine oil and insert them. 6. Install the camshafts. For additional information, refer to Camshafts See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshafts. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valve Stem Diameter Valve: Service and Repair Valve Stem Diameter Valve Stem Diameter NOTE: Refer to the Engine System Level for the specification. 1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valve Stem Diameter > Page 1629 Valve: Service and Repair Valve Inspection Valve Inspection 1. Inspect the following valve areas: 1. The end of the stem for grooves or scoring. 2. The valve face and the edge for pits, grooves or scores. 3. The valve head for signs of burning, erosion, warpage and cracking. 4. The valve margin for wear. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valve Stem Diameter > Page 1630 Valve: Service and Repair Valve Stem To Valve Guide Clearance Valve Stem to Valve Guide Clearance NOTE: Refer to the Engine System Level for the specification. NOTE: The valve stem diameter must be within specifications before checking valve stem-to-valve guide clearance. 1. NOTE: If necessary, use a magnetic base. Install a Valve Guide Clearance Gauge on the valve stem and install a Dial Indicator Gauge with Holding Fixture. Lower the valve until the clearance gauge contacts the upper surface of the valve guide. 2. Move the Valve Guide Clearance Gauge toward the Dial Indicator Gauge with Holding Fixture and zero the Dial Indicator Gauge. Move the Valve Guide Clearance Gauge away from the Dial Indicator Gauge with Holding Fixture and note the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Accessory Drive Accessory Drive Belt Routing Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt - Noise/Flutter Drive Belt: Testing and Inspection Drive Belt - Noise/Flutter Accessory Drive Component Tests Drive Belt - Noise/Flutter NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulleys have any fluids or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may occur. Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged or incorrectly aligned grooved pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on an accessory pulley under certain conditions. A short intermittent squeal may occur during engine start up and shut down or during very rapid engine acceleration and decelerations, such as: - Wide Open Throttle (WOT) 1-2 and 2-3 shifts or 2-3 and 3-4 back-out shifts on automatic transmissions. - WOT 1-2 and 2-3 shifts and any combination of rapid downshifting on manual transmissions. These special short-term transient events are expected, and are due to the higher system inertias required to meet the electrical and cooling demands on today's vehicle systems. Constant or reoccurring drive belt squeal can occur: - if the A/C discharge pressure goes above specifications: the A/C system is overcharged. - the A/C condenser core airflow is blocked. - the A/C anti-slugging strategy executes after a long hot heat soak. - if the A/C off equalized pressure (the common discharged and suction pressure that occurs after several minutes) exceeds specifications. - if any of the accessories or idler pulley(s) are damaged or have a worn or damaged bearing. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. - if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has been exposed to fluid contamination during vehicle operation, such as leaks from the power steering system, A/C system or cooling system, clean all pulleys with soap and water, rinse with clean water and install a new accessory drive belt. If the drive belt has been exposed to fluids in a localized area during routine vehicle service, such as replacement of hoses or fluids, the drive belt and pulleys should be washed with soap and water immediately (prior to starting the engine), and rinsed with clean water. - if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal installation wear range window, install a new accessory drive belt. - NOTE: The accessory drive belt tensioner arm should rotate freely without binding. Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt - Noise/Flutter > Page 1637 Drive Belt: Testing and Inspection Drive Belt - Incorrect Installation Accessory Drive Component Tests Drive Belt - Incorrect Installation NOTICE: Incorrect accessory drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the pulleys. Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive belt. Incorrect Installation Correct Installation With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking condition exists, proceed with the following: - Visually check the accessory drive belt tensioner for damage and wear, especially the mounting pad surface and arm alignment. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. If the tensioner arm is worn, the arm will be out of alignment. Either of these conditions will result in chirp and squeal noises. - With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Install new components as necessary. - Check all accessories, mounting brackets and the accessory drive belt tensioner for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck the accessory drive belt tracking. - Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware to specification. Recheck the accessory drive belt tracking. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View Drive Belt: Service and Repair Front End Accessory Drive (FEAD) - Exploded View Front End Accessory Drive (FEAD) - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View > Page 1640 Drive Belt: Service and Repair Accessory Drive Belt Accessory Drive Belt Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the pin-type retainer, 5 bolts and the RH splash shield. - To install, tighten to 9 Nm (80 lb-in). 3. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation Drive Belt Tensioner: Description and Operation Accessory Drive Belt Tensioner NOTE: The accessory drive belt tensioner must be replaced as a complete unit. Automatic tensioners are calibrated to provide the correct amount of tension to the belt for a given accessory drive system. Unless a spring or damping band within the tensioner assembly breaks, or some other mechanical part of the tensioner fails, there is no need to check the tensioner for correct tension. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Belt Tensioner - Mechanical Drive Belt Tensioner: Testing and Inspection Belt Tensioner - Mechanical Accessory Drive Component Tests Belt Tensioner - Mechanical The only mechanical check that needs to be made is a check for tensioner stick, grab or bind. 1. With the engine off, check routing of the accessory drive belt. Refer to the illustrations under Accessory Drive See: Description and Operation in the Description and Operation. 2. NOTE: The accessory drive belt tensioner spring is very strong and requires substantial force to release. Release the tension on the belt and detach the accessory drive belt from the tensioner. Carry out the following tests: - Move 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 tensioner spring. - Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition. - Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination and repair any leaks. 3. If the accessory drive belt tensioner does not meet the criteria in the previous step, install a new tensioner. If the accessory drive belt tensioner meets the criteria in the previous step, proceed to testing the tensioner dynamically. 4. If the tensioner is saturated with oil and grease internally, install a new tensioner. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Belt Tensioner - Mechanical > Page 1646 Drive Belt Tensioner: Testing and Inspection Belt Tensioner - Dynamics Accessory Drive Component Tests Belt Tensioner - Dynamics The accessory drive belt tensioner can be checked dynamically as follows: 1. With the engine running, observe the accessory drive belt tensioner movement. The accessory drive tensioner should move (respond) when the A/C clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory drive belt tensioner movement is excessive without A/C clutch cycling or engine acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in the belt) can cause excessive accessory drive belt tensioner movement. Check rideout condition by installing a new belt. If excessive accessory drive belt tensioner movement still exists, install a new accessory drive belt tensioner. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View Drive Belt Tensioner: Service and Repair Front End Accessory Drive (FEAD) - Exploded View Front End Accessory Drive (FEAD) - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View > Page 1649 Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner Accessory Drive Belt Tensioner Removal and Installation 1. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt from the tensioner pulley. 2. NOTE: The accessory drive belt tensioner must be replaced as a complete unit. Remove the 3 bolts and the accessory drive belt tensioner. - To install, tighten to 25 Nm (18 lb-ft). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration Engine Mount: Customer Interest Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration > Page 1658 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration Engine Mount: All Technical Service Bulletins Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration > Page 1664 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures Engine Mount: Procedures Powertrain/Drivetrain Mount Neutralizing NOTE: Refer to the appropriate system and procedure for special instructions on loosening and tightening mount fasteners. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. NOTICE: Do not twist or strain the powertrain/drivetrain mounts or damage to the mounts may occur. Start the vehicle and move it in forward 0.6-1.2 m (2-4 ft). Then move the vehicle in reverse the same distance. 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1667 Engine Mount: Removal and Replacement Engine Mount Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the engine coolant degas bottle. 3. Remove the DC/DC converter. For additional information, refer to Hybrid Drive Systems. 4. Install the Engine Support Bar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1668 5. Remove the engine mount bracket bolt. - To install, tighten to 115 Nm (85 lb-ft). 6. Use the Engine Support Bar to raise the engine 25 mm (0.98 in). 7. Remove the 3 nuts and the engine mount bracket. - To install, tighten to 115 Nm (85 lb-ft). 8. Remove the A/C tube bracket nut. - To install, tighten to 10 Nm (89 lb-in). 9. Rotate the A/C tube brackets off of the studs. - Reposition the A/C tubes to access the engine mount bolt. 10. Remove the 3 bolts and the engine mount. - To install, tighten to 48 Nm (35 lb-ft). 11. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View Idler Pulley: Service and Repair Front End Accessory Drive (FEAD) - Exploded View Front End Accessory Drive (FEAD) - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View > Page 1673 Idler Pulley: Service and Repair Accessory Drive Belt Idler Pulley Accessory Drive Belt Idler Pulley Removal and Installation All idler pulleys 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the pin-type retainer, 5 bolts and the RH splash shield. - To install, tighten to 9 Nm (80 lb-in). 3. Using the hex feature, rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the coolant pump pulley. Smooth idler pulley 4. Loosen the bolt and remove the smooth accessory drive belt idler pulley. - To install, tighten to 25 Nm (18 lb-ft). Grooved idler pulley 5. Remove the 2 bolts and the grooved accessory drive belt idler pulley and bracket. - To install, tighten to 25 Nm (18 lb-ft). 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure (hot @ 2,000 rpm) ........................................................................................................... ..............................................200-268 kPa (29-39 psi) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1678 Engine Oil Pressure: Testing and Inspection Engine Component Tests The following component tests are used to diagnose engine concerns. Oil Pressure Test 1. Disconnect and remove the Engine Oil Pressure (EOP) switch from the engine. 2. Connect the Engine Oil Pressure Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5. The oil pressure should be within specifications; for additional information, refer to the specification chart in the appropriate engine system. 6. If the pressure is not within specification, check the following possible sources: - Insufficient oil - Oil leakage - Worn or damaged oil pump - Oil pump screen cover and tube - Excessive main bearing clearance - Excessive connecting rod bearing clearance - Chain tensioner leak Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Page 1682 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Page 1683 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil ............................................................................................................................................ ......................................................... 5.0 qts. (4.73 L) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1688 Engine Oil: Fluid Type Specifications Ford Part Name US .......................................................................................................................................... Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Canada ................................................................................................................................................... Motorcraft SAE 5W-20 Super Premium Motor Oil Ford Part Number US .......................................................................................................................... ........................................................................................ X0-5W20-QSP Canada .............................. .............................................................................................................................................................. ......... CX0-5W20-LSP12 Ford Specifications ....................................................................................................................................... WSS-M2C930-A with API Certification Mark Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Tools and Equipment Oil Cooler: Tools and Equipment 1/2" Oil Cooler Line Rem. AST tool# 8023 Used to disconnect 1/2" transmission oil cooler lines. - Used for R and R of Transmission Oil Cooler Lines - Orange-Anodized Aluminum Construction - Quick line removal - Included in the #8110 Line Disconnect Set - Fits 2009 Escape with 6F Trans - Fits Ford Edge Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Tool is also available in the following kits: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Tools and Equipment > Page 1692 8110 - 10-Pc. Line Disconnect Set Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element Oil Filter: Service and Repair Oil Filter Element Oil Filter Element Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Loosen the oil filter drain plug. 3. Using a cup-style oil filter wrench, loosen the oil filter cover one turn. 4. Remove the oil filter drain plug and drain the engine oil from the oil filter and adapter. - Remove and discard the oil filter drain plug O-ring seal. 5. Remove the oil filter cover and oil filter element. - Discard the oil filter element. - Remove and discard the oil filter cover O-ring seal. Installation 1. Wipe clean the oil filter cover and mounting surface on the oil filter adapter. 2. NOTE: Lubricate the oil filter cover O-ring seal with clean engine oil. Install a new oil filter cover O-ring seal. 3. NOTICE: Do not overtighten the oil filter cover. Overtightening the oil filter cover may damage the cover or O-ring seal and result in a oil leak. Install a new oil filter element and the oil filter cover. - Using a cup-style oil wrench, tighten to 33 Nm (24 lb-ft). 4. NOTE: Lubricate the oil filter drain plug O-ring seal with clean engine oil. Install a new oil filter drain plug O-ring seal. 5. NOTICE: Do not overtighten the oil filter drain plug. Overtightening the oil filter drain plug may damage the drain plug, O-ring seal or cover and result in a oil leak. Install the oil filter drain plug. - Tighten to 10 Nm (89 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element > Page 1697 Oil Filter: Service and Repair Variable Camshaft Timing (VCT) System Oil Filter Variable Camshaft Timing (VCT) System Oil Filter Removal and Installation 1. Remove the Variable Camshaft Timing (VCT) solenoid. 2. Remove the plug and the VCT system oil filter from the intake camshaft thrust cap. - To install, tighten to 17 Nm (150 lb-in). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element > Page 1698 Oil Filter: Service and Repair Exploded View - Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element > Page 1699 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element > Page 1700 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element > Page 1701 Oil Filter: Service and Repair Exploded View - Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element > Page 1702 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Element > Page 1703 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter Oil Filter Adapter: Service and Repair Oil Filter Adapter Oil Filter Adapter Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the pin-type retainer (not shown), 5 bolts and the RH splash shield. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the Engine Oil Pressure (EOP) switch electrical connector. 4. If equipped, remove the oil filter element. For additional information, refer to Oil Filter Element See: Oil Filter/Service and Repair/Oil Filter Element. 5. If equipped, remove the spin-on oil filter. - To install, lubricate the spin-on oil filter gasket with clean engine oil and tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter. 6. NOTE: Discard the gasket. Remove the 4 bolts and the oil filter adapter. - To install, tighten to 25 Nm (18 lb-ft). 7. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 1708 Oil Filter Adapter: Service and Repair Exploded View - Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 1709 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 1710 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 1711 Oil Filter Adapter: Service and Repair Exploded View - Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 1712 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 1713 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Install the remaining oil pan bolts. Tighten in the sequence shown to................................................. .................................................................................................................25 Nm (18 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Lubrication Components - Exploded View Oil Pan: Service and Repair Engine Lubrication Components - Exploded View Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1719 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1720 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1721 Oil Pan: Service and Repair Oil Pan, Oil Pump Screen and Pickup Tube - Exploded View Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1722 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1723 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1724 Oil Pan: Service and Repair Oil Pan Oil Pan Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil, then install the drain plug. - Tighten to 28 Nm (21 lb-ft). 3. Remove the engine front cover. For additional information, refer to Engine Front Cover See: Timing Components/Timing Cover/Service and Repair. 4. Remove the 4 oil pan-to-bellhousing bolts. 5. Remove the 13 bolts and the oil pan. Installation 1. NOTICE: 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 traces of sealant. Clean and inspect all mating surfaces. 2. NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan. 3. Position the oil pan and install the 2 rear oil pan bolts finger-tight. 4. Using a suitable straightedge, align the front surface of the oil pan flush with the front surface of the engine block. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1725 5. Install the remaining oil pan bolts. - Tighten in the sequence shown to 25 Nm (18 lb-ft). 6. Install the 4 oil pan-to-bellhousing bolts. - Tighten to 48 Nm (35 lb-ft). 7. Install the engine front cover. For additional information, refer to Engine Front Cover See: Timing Components/Timing Cover/Service and Repair . 8. Fill the engine with clean engine oil. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1729 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the pin-type retainer, the 5 bolts and the RH splash shield. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the Engine Oil Pressure (EOP) switch electrical connector. 4. Remove the EOP switch. - To install, tighten to 15 Nm (133 lb-in). 5. To install, reverse the removal procedure. - Apply thread sealant with PTFE to the EOP switch threads. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 1732 Oil Pressure Sender: Service and Repair Exploded View - Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 1733 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 1734 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 1735 Oil Pressure Sender: Service and Repair Exploded View - Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 1736 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 1737 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Engine Lubrication Components - Exploded View Oil Pick Up/Strainer: Service and Repair Engine Lubrication Components - Exploded View Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1742 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1743 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1744 Oil Pick Up/Strainer: Service and Repair Oil Pan, Oil Pump Screen and Pickup Tube - Exploded View Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1745 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1746 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1747 Oil Pick Up/Strainer: Service and Repair Oil Pump Screen and Pickup Tube Oil Pump Screen and Pickup Tube Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the oil pan. For additional information, refer to Engine Lubrication Components Exploded View See: Oil Pan/Service and Repair/Engine Lubrication Components - Exploded View and Oil Pan See: Oil Pan/Service and Repair/Oil Pan. 3. NOTE: Discard the gasket and clean and inspect the gasket mating surfaces. Remove the 2 bolts and the oil pump screen and pickup tube. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure (hot @ 2,000 rpm) ........................................................................................................... ..............................................200-268 kPa (29-39 psi) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1752 Engine Oil Pressure: Testing and Inspection Engine Component Tests The following component tests are used to diagnose engine concerns. Oil Pressure Test 1. Disconnect and remove the Engine Oil Pressure (EOP) switch from the engine. 2. Connect the Engine Oil Pressure Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5. The oil pressure should be within specifications; for additional information, refer to the specification chart in the appropriate engine system. 6. If the pressure is not within specification, check the following possible sources: - Insufficient oil - Oil leakage - Worn or damaged oil pump - Oil pump screen cover and tube - Excessive main bearing clearance - Excessive connecting rod bearing clearance - Chain tensioner leak Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Intake Manifold: Specifications Intake Manifold Install the intake manifold gasket, intake manifold and 7 bolts. Tighten to........................................... .........................................................................................................................................................18 Nm (159 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold > Page 1757 Intake Manifold: Specifications Throttle Body To install, tighten to.............................................................................................................................. .........................................................10 Nm (89 lb-in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1758 Intake Manifold: Service and Repair Intake Manifold Intake Manifold (View 1 of 2) Intake Manifold (View 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1759 Removal and Installation 1. With vehicle in NEUTRAL, position it on a hoist. 2. Release the fuel pressure. 3. NOTICE: Before removing the high voltage cables, the vehicle electrical system must be completely shut down for at least 5 minutes to allow for the high voltage capacitors to discharge. Disable the vehicle high voltage electrical system. For additional information, refer to Hybrid Drive Systems. 4. Remove the cooling fan motor and shroud. 5. Remove the fuel rail. 6. Remove the Throttle Body (TB). 7. Remove the accessory drive belt tensioner. 8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector. 9. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector. 10. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector. 11. Disconnect the EVAP tube-to-EVAP canister purge valve quick connect coupling and the brake booster vacuum tube from the intake manifold. 12. Disconnect the Knock Sensor (KS) electrical connector and detach the 2 pin-type retainers. 13. Detach the 2 wiring retainers from the intake manifold near the throttle body mounting area. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1760 14. Detach the transaxle shift cable routing retainer from the intake manifold. 15. NOTE: The cylinder head side of the intake manifold is showing the location of the 7 bolts. Remove the 7 bolts and position the intake manifold aside to access the PCV hose connector. - To install, tighten to 18 Nm (159 lb-in). 16. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold. 17. Remove the intake manifold and gaskets. 18. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. To install, reverse the removal procedure. - Inspect and install new intake manifold gaskets if necessary. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Seal Crankshaft Rear Seal Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the flywheel. For additional information, refer to Flywheel See: Service and Repair/Removal and Replacement/Flywheel. 3. Drain the engine oil. - Install the drain plug. - Tighten to 28 Nm (21 lb-ft). 4. NOTICE: If the oil pan is not removed, damage to the rear oil seal retainer joint can occur. Remove the 17 bolts and the oil pan. 5. Remove the 6 bolts and the crankshaft rear oil seal with retainer plate. Installation 1. Using the Crankshaft Rear Main Oil Seal Installer, position the crankshaft rear oil seal with retainer plate onto the crankshaft. 2. Install the crankshaft rear oil seal with retainer plate and bolts. - Tighten in the sequence shown to 10 Nm (89 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 1766 3. NOTICE: 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 and metal surface cleaner to remove traces of sealant. Clean and inspect all the oil pan and cylinder block mating surfaces. 4. NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan. 5. Install the oil pan. Install the 2 oil pan bolts finger-tight. 6. Install the 4 bolts. - Tighten to 10 Nm (89 lb-in). 7. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb-ft). 8. Install the flywheel. For additional information, refer to Flywheel See: Service and Repair/Removal and Replacement/Flywheel. 9. Fill the engine with clean engine oil. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 1767 Crankshaft Main Bearing Seal: Service and Repair Exploded View - Flywheel and Crankshaft Rear Oil Seal Lower End Components - Exploded View Crankshaft Pulley and Crankshaft Front Oil Seal Flywheel and Crankshaft Rear Oil Seal Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 1768 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Crankshaft Front Seal Front Crankshaft Seal: Service and Repair Crankshaft Front Seal Crankshaft Front Seal Removal NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools or severe engine damage can occur. NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. Remove the crankshaft pulley. For additional information, refer to Lower End Components Exploded View See: Service and Repair/Removal and Replacement/Lower End Components - Exploded View and Crankshaft Pulley See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Crankshaft Pulley. 2. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the seal. Using the Oil Seal Remover, remove the crankshaft front seal. Installation 1. NOTE: Remove the through bolt from the Camshaft Front Oil Seal Installer. NOTE: Lubricate the oil seal with clean engine oil. Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Crankshaft Front Seal > Page 1773 2. Install the crankshaft pulley. For additional information, refer to Lower End Components Exploded View See: Service and Repair/Removal and Replacement/Lower End Components - Exploded View and Crankshaft Pulley See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Crankshaft Pulley. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Crankshaft Front Seal > Page 1774 Front Crankshaft Seal: Service and Repair Exploded View - Crankshaft Pulley and Crankshaft Front Oil Seal Lower End Components - Exploded View Crankshaft Pulley and Crankshaft Front Oil Seal Flywheel and Crankshaft Rear Oil Seal Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Crankshaft Front Seal > Page 1775 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valve Train Components - Exploded View Valve Guide Seal: Service and Repair Valve Train Components - Exploded View Valve Train Components - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valve Train Components - Exploded View > Page 1780 Valve Guide Seal: Service and Repair Valve Seals Valve Seals Removal NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in NEUTRAL, position it on a hoist. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valve Train Components - Exploded View > Page 1781 2. Remove the camshafts. For additional information, refer to Camshafts See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshafts. 3. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. Remove and inspect the valve tappets. 4. Remove the spark plugs. 5. NOTICE: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect the compressed air from the cylinder until the valve spring, valve spring retainer and valve collet is installed. Any loss of air pressure will allow the valve to fall into the cylinder. Connect the compressed air supply to the No. 1 cylinder. 6. NOTE: Place all parts in order to one side. Apply compressed air to the cylinder and remove the valve spring. - Using the Valve Spring Compressors, compress the valve spring and remove the valve collet, using some grease and a small screwdriver. - Remove the valve spring retainer and the valve spring. 7. Using the Slide Hammer and the Valve Stem Oil Seal Remover, remove and discard the valve seal. Installation 1. Install the valve stem seal installation sleeve. 2. Using the Valve Stem Oil Seal Installer, install the valve seal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valve Train Components - Exploded View > Page 1782 3. NOTE: Check the seating of the valve collet. Using the Valve Spring Compressors, install the valve spring. - Insert the valve spring and the valve spring retainer. - Compress the valve spring and install the valve collet using some grease and a small screwdriver. 4. Disconnect the compressed air supply. 5. Install the spark plugs. 6. Repeat the appropriate removal and installation steps for all of the other cylinders. 7. Coat the valve tappets with clean engine oil and insert them. 8. Install the camshafts. For additional information, refer to Camshafts See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshafts. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1787 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the pin-type retainer, the 5 bolts and the RH splash shield. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the Engine Oil Pressure (EOP) switch electrical connector. 4. Remove the EOP switch. - To install, tighten to 15 Nm (133 lb-in). 5. To install, reverse the removal procedure. - Apply thread sealant with PTFE to the EOP switch threads. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 1790 Oil Pressure Sender: Service and Repair Exploded View - Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 1791 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 1792 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 1793 Oil Pressure Sender: Service and Repair Exploded View - Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 1794 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 1795 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft sprocket bolts....................................................................................................................... ...........................................................72 Nm (53 lb-ft) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams Timing Chain: Diagrams NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur. NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only. Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). Remove the engine plug bolt. NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position until the timing drive components and crankshaft pulley are installed. Install the Crankshaft TDC Timing Peg. NOTICE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons. NOTE: Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket. Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket. - The crankshaft sprocket flange must be facing away from the engine block. Install the oil pump chain, sprocket and bolt. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Page 1803 NOTICE: The Camshaft Alignment Plate 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time. Install the timing chain. NOTICE: The Camshaft Alignment Plate 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. NOTE: Do not install the crankshaft pulley bolt at this time. NOTE: Apply clean engine oil on the seal area before installing. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Page 1804 NOTICE: Only hand-tighten the 6 mm bolt or damage to the front cover can occur. NOTE: This step will correctly align the crankshaft pulley to the crankshaft. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only. NOTE: Do not reuse the crankshaft pulley bolt. Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt. Remove the 6 mm x 18 mm bolt. Remove the Crankshaft TDC Timing Peg. Remove the Camshaft Alignment Plate. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Page 1805 NOTE: Only turn the engine in the normal direction of rotation. Turn the crankshaft clockwise one and three-fourth turns. Install the Crankshaft TDC Timing Peg. NOTE: Only turn the engine in the normal direction of rotation. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley. - If it is not possible to install the bolt, the engine valve timing must be corrected. Install the Camshaft Alignment Plate to check the position of the camshafts. - If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Page 1806 Remove the Camshaft Alignment Plate. Remove the 6 mm x 18 mm bolt. Remove the Crankshaft TDC Timing Peg. Install the engine plug bolt. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston. Tighten to.............................................................................................................................................. ........................................................10 Nm (89 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 1810 Timing Chain Tensioner: Service and Repair Timing Drive Components Removal NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools or severe engine damage can occur. NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the engine front cover. For additional information, refer to Engine Front Cover See: Timing Cover/Service and Repair. 3. Compress the timing chain tensioner in the following sequence. 1. Using a small pick, release and hold the ratchet mechanism. 2. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner. 3. Insert a paper clip into the hole to retain the tensioner. 4. Remove the 2 bolts and timing chain tensioner. 5. Remove the timing chain tensioner arm. 6. Remove the timing chain. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 1811 7. Remove the 2 bolts and the timing chain guide. 8. NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket. 9. NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the camshaft phaser and sprocket. Installation 1. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time. 2. Install the timing chain guide and the 2 bolts. - To install, tighten to 10 Nm (89 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 1812 3. Install the timing chain. 4. Install the timing chain tensioner arm. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps. 5. NOTICE: Do not compress the ratchet assembly. This will damage the ratchet assembly. Using the edge of a vise, compress the timing chain tensioner plunger. 6. Using a small pick, push back and hold the ratchet mechanism. 7. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing. 8. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 1813 9. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston. - Tighten to 10 Nm (89 lb-in). 10. NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. - Tighten to 72 Nm (53 lb-ft). 11. Install the engine front cover. For additional information, refer to Engine Front Cover See: Timing Cover/Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications: Tighten the 8-mm bolts to............................................................................................. ................................................................................10 Nm (89 lb-in). Tighten the 13-mm bolts to....... .............................................................................................................................................................. .......48 Nm (35 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1817 Timing Cover: Service and Repair Engine Front Cover Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1818 Removal NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur. NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt and tensioner. 3. Remove the crankshaft pulley. For additional information refer to Crankshaft Pulley See: Cylinder Block Assembly/Harmonic Balancer Crankshaft Pulley/Service and Repair/Crankshaft Pulley. 4. Remove the engine mount. For additional information, refer to Engine Mount See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Removal and Replacement. 5. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the seal. Using the Oil Seal Remover, remove the crankshaft front seal. 6. Remove the 3 bolts and the coolant pump pulley. 7. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 8. Remove the 2 bolts and the CKP sensor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1819 9. Remove the bolts and the engine front cover. Installation 1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Clean and inspect the mounting surfaces of the engine and the front cover. 2. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover. 3. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications: - Tighten the 8-mm bolts to 10 Nm (89 lb-in). - Tighten the 13-mm bolts to 48 Nm (35 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1820 4. NOTE: Remove the through bolt from the Camshaft Front Oil Seal Installer. NOTE: Lubricate the oil seal with clean engine oil. Using the Camshaft Front Oil Seal Installer, install the crankshaft front seal. 5. Install the coolant pump pulley and the 3 bolts. - Tighten to 20 Nm (177 lb-in). 6. Install the engine mount. For additional information, refer to Engine Mount See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Removal and Replacement. 7. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley See: Cylinder Block Assembly/Harmonic Balancer Crankshaft Pulley/Service and Repair/Crankshaft Pulley. 8. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover. 9. Install the CKP sensor and the 2 bolts. - Do not tighten the bolts at this time. 10. Using the Crankshaft Sensor Aligner, adjust the CKP sensor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1821 - Tighten the 2 CKP bolts to 7 Nm (62 lb-in). 11. Connect the CKP sensor electrical connector. 12. Remove the 6 mm x 18 mm bolt. 13. Install the accessory drive belt and tensioner. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1826 Variable Valve Timing Actuator: Description and Operation Variable Camshaft Timing (VCT) System Overview The intake phase shifting (IPS) VCT system enables rotation of the intake camshaft relative to the crankshaft rotation as a function of engine operating conditions. The VCT system has several operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on a constant angle, limited by engine oil temperature and engine RPM. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. Variable Camshaft Timing (VCT) System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel indicates the CMP signal for that bank. A crankshaft position (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT), cylinder head temperature (CHT), CMP, accelerator pedal position (APP) sensor (via requested torque), mass air flow (MAF), and CKP sensors to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on engine oil temperature and engine speed inputs. During cold start emissions reduction mode, the camshaft position is determined via engine speed and estimates of engine coolant temperature and catalyst temperature (estimated from other sensors already used such as IAT/CHT/MAF/CKP). During part and wide open throttle, the camshaft position is determined by engine RPM, load and accelerator pedal position. The VCT system does not operate until the engine is at normal operating oil temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a default position if a concern is detected. A related diagnostic trouble code (DTC) is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the two halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. VCT System Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Filter > Component Information > Service and Repair Variable Valve Timing Filter: Service and Repair Variable Camshaft Timing (VCT) System Oil Filter Removal and Installation 1. Remove the Variable Camshaft Timing (VCT) solenoid. 2. Remove the plug and the VCT system oil filter from the intake camshaft thrust cap. - To install, tighten to 17 Nm (150 lb-in). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair Variable Valve Timing Solenoid: Service and Repair Variable Camshaft Timing (VCT) Oil Control Solenoid Removal and Installation 1. Remove the valve cover. 2. Remove the bolt and the Variable Camshaft Timing (VCT) oil control solenoid. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure Key ON Engine OFF (KOEO)............................................................................................................... .........................................................379 kPa (55 psi) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1837 Fuel Pressure: Testing and Inspection Fuel System Pressure Test WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. NOTE: Early build 3.0L engines are equipped with a Schrader valve on the fuel rail. Late build 3.0L engines do not have a Schrader valve. All vehicles 1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. For additional information, refer to Battery. Vehicles with 2.5L engine 3. Disconnect the fuel tube-to-fuel rail quick connect coupling. For additional information, refer to Quick Connect Coupling See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Quick Connect Coupling. 4. Install the Fuel Pressure Test Kit between the fuel tube and the fuel rail. Vehicles with early build 3.0L engine 5. Remove the fuel rail Schrader valve cap. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1838 6. Install the Fuel Pressure Test Kit to the fuel rail Schrader valve. Vehicles with late build 3.0L engine 7. Disconnect the fuel jumper tube-to-fuel tube quick connect coupling. For additional information, refer to Quick Connect Coupling See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Quick Connect Coupling. 8. Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel tube. All vehicles 9. NOTE: The Fuel Pump (FP) fuse was removed previously to release the fuel system pressure and must be installed to test the fuel system pressure. Install the FP fuse. 10. Connect the battery ground cable. For additional information, refer to Battery. 11. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 12. NOTE: Upon completion of the fuel system pressure test, open the drain valve on the Fuel Pressure Test Kit and release fuel system pressure and drain any residual fuel into a suitable container prior to removing the tool. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Measured/PID Values Hot Idle ................................................................................................................................................ ............................................................. 1072 RPM Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Intake Air System Components - Exploded View Air Cleaner (ACL) Assembly and Outlet Pipe Air Cleaner (ACL) Intake Pipe Intake Air Resonator Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1846 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel System Pressure Release WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. NOTE: The Fuel Pump (FP) fuse is located in the Battery Junction Box (BJB), location 22. Remove the FP fuse. 2. Start the engine and allow it to idle until it stalls. 3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released. 4. Turn the ignition switch to the OFF position. 5. When the fuel system service is complete, install the FP fuse. 6. NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for leaks prior to starting the engine. Start the vehicle and check the fuel system for leaks. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Firing Order Firing Order: Specifications Firing Order Firing Order.......................................................................................................................................... .........................................................................1-3-4-2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Firing Order > Page 1855 Firing Order: Specifications Engine Cylinder Identification Engine Engine Cylinder Identification Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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..................................................................................................................................... ....................................1.08-1.18 mm (0.042-0.046 in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 1860 Spark Plug: Specifications Torque Specifications Spark plugs........................................................................................................................................... ........................................................12 Nm (106 lb-in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1861 Spark Plug: Application and ID Spark plug............................................................................................................................................ .............................................................AYSF-32-YPC Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1862 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. - Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. - Install a new spark plug. 2. Check for oil fouling. - Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. - Correct the oil leak concern. - Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. Install new spark plugs. 4. Inspect for normal burning. - Check for light tan or gray deposits on the firing tip. 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. Install a new spark plug. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1863 6. Inspect for overheating, identified by white or light gray spots and with a bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. - Install new spark plugs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View Spark Plug: Service and Repair Engine Ignition Components - Exploded View Engine Ignition Components - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 1866 Spark Plug: Service and Repair Spark Plugs Spark Plugs Removal and Installation 1. Remove the ignition coils. For additional information, refer to Ignition Coil-On-Plug See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil-On-Plug. 2. NOTICE: Only use hand tools when removing or installing the spark plugs, or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material in the spark plug well prior to removing the spark plugs. Remove the spark plugs. - To install, tighten to 12 Nm (106 lb-in). 3. Inspect the spark plugs. 4. To install, reverse the removal procedure. - Adjust the spark plug gap as necessary. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil meeting Ford specification on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are worn or damaged. 2. If compression does not improve, valves are sticking or not seating correctly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so the lowest reading is within 75% of the highest reading. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1870 Compression Check: Testing and Inspection Engine Component Tests The following component tests are used to diagnose engine concerns. Compression Test - Hybrid The compression test requires cranking the engine a minimum of 5 compression strokes with the throttle plate in the wide-open position for each cylinder. The engine cranking diagnostic mode must be used to crank the engine and the brake/accelerator pedals must be used to position the throttle plate during the compression test. The engine cranking diagnostic mode is a PCM strategy which is separate from the normal operating strategy. It allows the engine to crank in a similar fashion as a conventional vehicle with the fuel disabled. When in this mode, the PCM commands the Transmission Control Module (TCM) to spin the generator, which cranks the engine with the speed between 900 and 1,200 rpm. The engine will crank as long as the traction battery state of charge stays greater than 35%. 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level. Operate the vehicle until the engine is at normal operating temperature. 2. Using the Vehicle Communication Module (VCM), access the Battery Control Module (BCM) and monitor the traction battery state of charge PID. If the monitored PID displays the state of charge below 45%, start and idle the engine with full A/C ON. When the traction battery state of charge exceeds 45%, the engine cranking diagnostic mode can be activated. 3. Turn the ignition switch to the OFF position, then remove all the spark plugs. 4. Install a compression gauge in the No. 1 cylinder. 5. Activate the cranking diagnostic mode as follows: - Apply the parking brake. - Place the gear selector in the PARK position. - Verify the key is in the OFF position. - NOTE: Do not crank the engine. Turn the key to the ON position with the engine OFF. - Within 5 seconds of the key in the ON position, fully apply the accelerator pedal and hold for 10 seconds. - Within 5 seconds release the accelerator pedal, shift the gear selector to the NEUTRAL position and fully apply the accelerator pedal. - Hold the accelerator pedal fully applied for 10 seconds. - Release the accelerator pedal and shift the gear selector to the PARK position. If the sequence is correctly executed, the instrument cluster hazard indicator (red triangle) flashes once per second when the gear selector is shifted to the PARK position. The PCM exits the engine cranking diagnostic mode when the traction battery state of charge drops below 35%, the gear selector is shifted to any gear other than PARK or when the ignition key is turned to the OFF or ACC position. 6. NOTE: If the ignition key stays in the START position for 15 seconds or longer, the PCM may set DTC P2535. NOTE: If the brake pedal is not depressed and held prior to depressing the accelerator pedal, the throttle plate will fail to open. Crank the engine as follows: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1871 - Depress and hold the brake pedal. - Fully depress and hold the accelerator pedal. - Turn the key to the START position and crank the engine a minimum of 5 compression strokes and record the highest reading. Return the key to the ON position. - Release the accelerator pedal. - Release the brake pedal. 7. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 8. Position the key to the OFF position to deactivate the cranking diagnostic mode. 9. Clear all DTCs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications NOTE: The nominal clearance is: intake:............................................................................................. .........................................................................................................0.25 mm (0.0095 in). exhaust:..... .............................................................................................................................................................. .................................0.30 mm (0.0115 in). The acceptable clearances after being fully installed are: intake:........................................................ .............................................................................................................................0.22-0.28 mm (0.008-0.011 in). exhaust:..................................................................................................................... ..............................................................0.27-0.33 mm (0.010-0.013 in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1875 Valve Clearance: Adjustments Valve Clearance Check 1. Remove the valve cover. For additional information, refer to Valve Cover See: Service and Repair/Removal and Replacement/Valve Cover. 2. Remove the 5 bolts, the pin-type retainer (not shown) and the RH splash shield. - To install, tighten to 9 Nm (80 lb-in). 3. NOTE: Turn the engine clockwise only, and only use the crankshaft bolt. NOTE: Before removing the camshafts, measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure the clearance of each valve and record its location. 4. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: The nominal clearance is: intake: 0.25 mm (0.0095 in). - exhaust: 0.30 mm (0.0115 in). The acceptable clearances after being fully installed are: - intake: 0.22-0.28 mm (0.008-0.011 in). - exhaust: 0.27-0.33 mm (0.010-0.013 in). Select tappets using this formula: tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. Select the closest tappet size to the ideal tappet thickness available and mark the installation location. 5. If any tappets do not measure within specifications, install new tappets in these locations. For additional information, refer to Valve Train Components - Exploded View See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Valve Train Components - Exploded View and Valve Tappets See: Camshaft, Lifters and Push Rods/Lifter / Lash Adjuster/Service and Repair/Removal and Replacement/Valve Tappets. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Install the new O-ring, coolant pump and the 3 bolts. Tighten to......................................................... .............................................................................................................................................10 Nm (89 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1879 Water Pump: Description and Operation Motor Electronics Cooling System (MECS) Pump The motor electronics cooling system is required to maintain an acceptable temperature for the transaxle and the DC/DC converter. The system temperature is monitored by the motor electronics coolant temperature (MECT) sensor, which is an input to the PCM. The PCM commands the MECS pump using the MECS pump relay. The MECS pump is commanded on whenever the traction battery contactors are closed. The coolant in the system flows in a loop from the MECS pump, to the transaxle, then into the MECS radiator bottom hose port, out of the top hose port of the MECS radiator, into the DC/DC converter, and back into the MECS pump. The cooling system has a degassing system that is connected in parallel between the MECS radiator and the MECS pump. The degassing system bleeds air/gases into the degas reservoir. Motor Electronics Cooling System (MECS) Pump Motor Electronics Coolant Flow Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1880 Water Pump: Service and Repair Coolant Pump Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Cooling System/Service and Repair. 3. Remove the accessory drive belt. 4. Remove the 3 bolts and the coolant pump pulley. - To install, tighten to 20 Nm (177 lb-in). 5. NOTICE: Make sure the coolant pump is correctly seated to the engine block before installing and tightening the fasteners, or damage to the coolant pump may occur. Remove the 3 bolts and the coolant pump. - Remove and discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). 6. To install, reverse the removal procedure. - Lubricate the O-ring seal with clean engine coolant. 7. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Cooling System/Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Auxiliary Water Pump > Component Information > Locations > M/E Coolant Pump Motor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Auxiliary Water Pump > Component Information > Locations > M/E Coolant Pump Motor > Page 1886 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Auxiliary Water Pump > Component Information > Diagrams > Heater Pump Motor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Auxiliary Water Pump > Component Information > Diagrams > Heater Pump Motor > Page 1889 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Auxiliary Water Pump > Component Information > Diagrams > Page 1890 Auxiliary Water Pump: Description and Operation Heater Pump The heater pump is required to maintain engine coolant flow to the heater core for passenger compartment heating when the engine is not running. The PCM commands the heater pump on by energizing the heater pump control relay (HPCR). The pump is commanded on when the following conditions are met: - The key is in the ON/START position. - The engine coolant temperature is above a minimum threshold 0°C (32°F) nominal. - The inferred ambient temperature is below a calibrated value 32°C (90°F) nominal. - The engine speed is below a calibrated threshold (nominal 4,000 RPM) including engine OFF. - The climate control mode switch is in any position other than OFF. The pump is off when the climate control mode switch is set to OFF. Heater Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Auxiliary Water Pump > Component Information > Diagrams > Page 1891 Auxiliary Water Pump: Service and Repair Auxiliary Coolant Flow Pump Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the LH lower engine splash shield. 4. Release the clamp and disconnect the auxiliary coolant pump-to-thermostat hose. 5. Release the clamp and disconnect the heater outlet hose. 6. Disconnect the auxiliary coolant flow pump electrical connector. 7. Remove the 2 auxiliary coolant flow pump bolts. - To install, tighten to 4 Nm (35 lb-in). 8. Remove the auxiliary coolant flow pump and rubber bracket assembly. 9. NOTE: Lubricate the coolant hoses with plain water only if needed. Do not use soap or other detergents. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Auxiliary Water Pump > Component Information > Diagrams > Page 1892 - Fill the engine cooling system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component Information > Service and Repair Thermostat Bypass Hose: Service and Repair Bypass Tube Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair. 3. Remove the intake manifold. 4. Disconnect and remove the coolant bypass tube. 5. To install, reverse the removal procedure. 6. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine coolant ..................................................................................................................................... ............................................................. 7.4 qts (7.0L) Motor/Electronics (M/E) Coolant .......................................................................................................... ......................................................... 3.7 qts. (3.5 L) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1900 Coolant: Fluid Type Specifications Ford Part Name Motorcraft Premium Gold Engine Coolant with Bettering agent (yellow-colored) Ford Part Number ................................................................................................................................ ...................................................................... VC-7-B Ford Specification ................................................................................................................................ .................................................... WSS-M97B51-A1 Note: Add the coolant type originally equipped in your vehicle. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair Coolant Reservoir: Service and Repair Degas Bottle Removal and Installation 1. WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury. NOTE: The degas bottle has 2 separate reservoirs. The front (larger) reservoir is part of the engine cooling system. The rear (smaller) reservoir is part of the Motor Electronics Cooling System (MECS). Release the pressure in the cooling system by slowly turning the pressure relief cap one half-turn counterclockwise. When the pressure is released, remove the pressure relief cap. 2. Using hose clamp pliers, clamp the engine coolant return hose and the motor electronics coolant return hose. 3. Using a suitable suction device, siphon the coolant from the degas bottle. 4. Disconnect the MECS coolant vent hose. 5. Disconnect the 2 engine coolant vent hoses. 6. Detach the pin-type retainer from the degas bottle. 7. Remove the degas bottle bolt and nut. - To install, tighten the nut to 6 Nm (53 lb-in) and the bolt to 8 Nm (71 lb-in). 8. Lift the degas bottle up and disconnect the engine coolant and MECS coolant return hoses. - Remove the degas bottle. 9. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Page 1904 10. Fill the degas bottle. Refer to Cooling System Draining, Filling and Bleeding See: Service and Repair and Motor Electronics Cooling System (MECS) Draining and Filling in Transmission Cooler, A/T for the recommended coolant mixtures and fill levels. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Engine Cooling Fan Motor 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Engine Cooling Fan Motor 1 > Page 1910 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1913 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1914 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1915 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1916 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1917 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1918 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1919 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1920 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1921 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1922 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1923 Radiator Cooling Fan Motor: 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1924 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1925 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1926 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1927 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1928 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1929 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1930 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1931 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1932 Radiator Cooling Fan Motor: Connector Views Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1933 Radiator Cooling Fan Motor: Service and Repair Cooling Fan Motor and Shroud Removal and Installation 1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the front bumper cover. 3. Remove the 2 front impact severity sensors. For additional information, refer to Air Bag Systems. 4. Remove the 4 bolts and the 2 radiator brackets. - To install, tighten to 10 Nm (89 lb-in). 5. NOTE: Mark the hood latch position prior to removal of the bolts. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1934 Remove the 2 bolts, the nut and position aside the hood latch. - To install, tighten to 9 Nm (80 lb-in). 6. Remove the center support lower bolt. - To install, tighten to 10 Nm (89 lb-in). 7. Remove the bolt and the center support. - To install, tighten to 10 Nm (89 lb-in). 8. Remove the 2 bolts and position the auxiliary coolant pump aside. - To install, tighten to 7 Nm (62 lb-in). 9. Disconnect the cooling fan resistor electrical connector. 10. Disconnect the 2 cooling fan electrical connectors. 11. Remove the 6 cooling fan bolts. - To install, tighten to 8 Nm (71 lb-in). 12. NOTE: Remove the LH cooling fan first and slide the RH cooling fan to the left side to remove. Remove the LH and the RH cooling fans. 13. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Fan Control Relay 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Fan Control Relay 1 > Page 1939 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Fan Control Relay 1 > Page 1940 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Resistor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Tools and Equipment Fan Clutch: Tools and Equipment Fan Clutch Holding Tool AST tool# 8005 Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan. 2009 Suggested user price: $41.20 Assenmacher Specialty Tools 1 800 525 2943 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 1951 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 1952 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which the resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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 varying the resistance of the passive sensor causes a variation in total current flow. The CHT sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor provides 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 then initiates 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 See: Powertrain Management/Computers and Control Systems/Description and Operation/Powertrain Control Software Fail-Safe Cooling Strategy. Cylinder Head Temperature (CHT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 1953 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. Detach the Cylinder Head Temperature (CHT) sensor cover and position aside. 2. Disconnect the CHT sensor electrical connector. 3. Remove the CHT sensor. - To install, tighten to 12 Nm (106 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Hybrid Drive Coolant Temperature Sensor > Component Information > Description and Operation Hybrid Drive Coolant Temperature Sensor: Description and Operation Motor Electronics Coolant Temperature (MECT) Sensor The MECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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. A thermistor type sensor is considered a passive sensor. 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 MECT provides motor electronics cooling system temperature information to the PCM. The PCM uses this information for determining when to activate the cooling system fans and indicate over-temperature. Typical Thread Type Sensor Motor Electronics Coolant Temperature (MECT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair Fan Shroud: Service and Repair Cooling Fan Motor and Shroud Removal and Installation 1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the front bumper cover. 3. Remove the 2 front impact severity sensors. For additional information, refer to Air Bag Systems. 4. Remove the 4 bolts and the 2 radiator brackets. - To install, tighten to 10 Nm (89 lb-in). 5. NOTE: Mark the hood latch position prior to removal of the bolts. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 1960 Remove the 2 bolts, the nut and position aside the hood latch. - To install, tighten to 9 Nm (80 lb-in). 6. Remove the center support lower bolt. - To install, tighten to 10 Nm (89 lb-in). 7. Remove the bolt and the center support. - To install, tighten to 10 Nm (89 lb-in). 8. Remove the 2 bolts and position the auxiliary coolant pump aside. - To install, tighten to 7 Nm (62 lb-in). 9. Disconnect the cooling fan resistor electrical connector. 10. Disconnect the 2 cooling fan electrical connectors. 11. Remove the 6 cooling fan bolts. - To install, tighten to 8 Nm (71 lb-in). 12. NOTE: Remove the LH cooling fan first and slide the RH cooling fan to the left side to remove. Remove the LH and the RH cooling fans. 13. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection > Heater Core Heater Core: Testing and Inspection Heater Core Climate Control System Component Tests Heater Core 1. NOTE: 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 as follows: Inspect for evidence of coolant leakage at the heater hose to heater core attachments. A coolant leak in the heater hose could follow the heater core tube to the heater core and appear as a leak in the heater core. 2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specified clamps can cause leakage at the heater hose connection and damage the heater core. Check the integrity of the heater hose clamps. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 1965 Heater Core: Testing and Inspection Heater Core - Plugged Climate Control System Component Tests Heater Core - Plugged 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, check the heater core inlet and outlet hoses to see if they are hot. 4. If the outlet only is not hot: - the heater core may have an air pocket. - the heater core may be plugged. 5. If the inlet only is not hot, the thermostat may not be working correctly. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 1966 Heater Core: Testing and Inspection Heater Core - Pressure Test Climate Control System Component Tests Heater Core - Pressure Test Use the Pressure Test Kit to carry out the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Drain the coolant from the cooling system. 2. Disconnect the heater hoses from the heater core. 3. Install a short piece of heater hose, approximately 101 mm (4 in) long on each heater core tube. 4. Fill the heater core and heater hoses with water and install plug BT-7422-B and adapter BT-7422-A from the Pressure Test Kit. Secure the heater hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Pressure Test Kit to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of 3 minutes. 8. If the pressure drops, check the heater hose connections to the core tubes for leaks. If the heater hoses do not leak, remove the heater core from the vehicle. 9. Carry out the Bench Test. See: Heater Core - Bench Test Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 1967 Heater Core: Testing and Inspection Heater Core - Bench Test Climate Control System Component Tests 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 in) test heater hoses with plug and adapter to the core tubes. Then connect the Pressure Test Kit to the adapter. 4. Apply 138 kPa (20 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection > Page 1968 Heater Core: Service and Repair Heater Core Removal and Installation NOTE: If a heater core leak is suspected, the heater core must be leak tested before the heater core is removed. NOTE: Use only the approved coolant for this vehicle. 1. Remove the heater core and evaporator core housing. For additional information, refer to Heater Core And Evaporator Core Housing See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Heater Core And Evaporator Core Housing. 2. Remove the dash panel seal. 3. Remove the heater core bracket screw and the heater core bracket. - To install, tighten to 3 Nm (27 lb-in). 4. Remove the heater core. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Hybrid Drive Coolant Temperature Sensor > Component Information > Description and Operation Hybrid Drive Coolant Temperature Sensor: Description and Operation Motor Electronics Coolant Temperature (MECT) Sensor The MECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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. A thermistor type sensor is considered a passive sensor. 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 MECT provides motor electronics cooling system temperature information to the PCM. The PCM uses this information for determining when to activate the cooling system fans and indicate over-temperature. Typical Thread Type Sensor Motor Electronics Coolant Temperature (MECT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair Radiator: Service and Repair Radiator Removal and Installation 1. With vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair. 3. Drain the Motor Electronics Cooling System (MECS). 4. Remove the cooling fan motor and shroud. For additional information, refer to Cooling Fan Motor and Shroud See: Radiator Cooling Fan/Radiator Cooling Fan Motor/Service and Repair. 5. Disconnect the upper hose from the MECS radiator. 6. Remove the 2 MECS radiator-to-engine radiator bolts and position the MECS radiator aside. - To install, tighten to 6 Nm (53 lb-in). 7. Remove the 2 A/C condenser-to-radiator bolts and position the A/C condenser aside. - To install, tighten to 10 Nm (89 lb-in). 8. Disconnect the lower radiator hose from the radiator. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 1975 9. Disconnect the degas bottle return hose from the radiator. 10. Disconnect the engine coolant vent hose from the radiator. 11. Disconnect the upper radiator hose from the radiator. 12. Remove the radiator. 13. To install, reverse the removal procedure. 14. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair. 15. Fill and bleed the MECS. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Auxiliary Water Pump Relay > Component Information > Locations > M/E Coolant Pump Relay Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Auxiliary Water Pump Relay > Component Information > Locations > M/E Coolant Pump Relay > Page 1981 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Fan Control Relay 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Fan Control Relay 1 > Page 1986 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Fan Control Relay 1 > Page 1987 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 1993 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 1994 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which the resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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 varying the resistance of the passive sensor causes a variation in total current flow. The CHT sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor provides 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 then initiates 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 See: Powertrain Management/Computers and Control Systems/Description and Operation/Powertrain Control Software Fail-Safe Cooling Strategy. Cylinder Head Temperature (CHT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 1995 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. Detach the Cylinder Head Temperature (CHT) sensor cover and position aside. 2. Disconnect the CHT sensor electrical connector. 3. Remove the CHT sensor. - To install, tighten to 12 Nm (106 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Hybrid Drive Coolant Temperature Sensor > Component Information > Description and Operation Hybrid Drive Coolant Temperature Sensor: Description and Operation Motor Electronics Coolant Temperature (MECT) Sensor The MECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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. A thermistor type sensor is considered a passive sensor. 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 MECT provides motor electronics cooling system temperature information to the PCM. The PCM uses this information for determining when to activate the cooling system fans and indicate over-temperature. Typical Thread Type Sensor Motor Electronics Coolant Temperature (MECT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection Thermostat: Testing and Inspection Engine Cooling Component Tests Thermostat A new thermostat should be installed only after the following tests and checks have been carried out: - Pinpoint Test A, B or C - Thermostat Visual Inspection Thermostat Visual Inspection 1. Remove the thermostat. 2. Examine the thermostat for signs of damage including: - Valve not fully seated (light visible through the valve) - Foreign material lodged in the main valve - Bent or broken frame or flange - Bent or broken spring - Bent or broken valve or valve stem - Wax leaking from wax reservoir or a bulge in the reservoir - Any other damage or distortion 3. NOTE: If no damage is found during the inspection, do not attempt to open the thermostat using hot water or other heat sources. This method is not an accurate means to test the function of the thermostat and may damage the thermostat. If damage is found during the inspection, remove any foreign material or broken pieces and install a new thermostat. 4. If no damage is found during the inspection, continue troubleshooting the system concern. Go to the Symptom Chart for further instructions. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair Thermostat Housing: Service and Repair Thermostat Housing Removal and Installation NOTE: The thermostat and thermostat housing are serviced as an assembly. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair. 3. Remove the accessory drive belt tensioner. 4. NOTE: The view of the thermostat housing bolts is obstructed by A/C and engine components. However, the bolts can be removed using 1/4-in drive hand tools. Remove the 3 bolts and reposition the thermostat housing to gain access to the hose clamps. - Remove and discard the gasket. - To install, tighten to 10 Nm (89 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 2005 5. Disconnect the heater hose at the thermostat housing. 6. Disconnect the lower radiator hose at the thermostat housing. 7. To install, reverse the removal procedure. - Install a new gasket. 8. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Install the new O-ring, coolant pump and the 3 bolts. Tighten to......................................................... .............................................................................................................................................10 Nm (89 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2009 Water Pump: Description and Operation Motor Electronics Cooling System (MECS) Pump The motor electronics cooling system is required to maintain an acceptable temperature for the transaxle and the DC/DC converter. The system temperature is monitored by the motor electronics coolant temperature (MECT) sensor, which is an input to the PCM. The PCM commands the MECS pump using the MECS pump relay. The MECS pump is commanded on whenever the traction battery contactors are closed. The coolant in the system flows in a loop from the MECS pump, to the transaxle, then into the MECS radiator bottom hose port, out of the top hose port of the MECS radiator, into the DC/DC converter, and back into the MECS pump. The cooling system has a degassing system that is connected in parallel between the MECS radiator and the MECS pump. The degassing system bleeds air/gases into the degas reservoir. Motor Electronics Cooling System (MECS) Pump Motor Electronics Coolant Flow Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2010 Water Pump: Service and Repair Coolant Pump Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair. 3. Remove the accessory drive belt. 4. Remove the 3 bolts and the coolant pump pulley. - To install, tighten to 20 Nm (177 lb-in). 5. NOTICE: Make sure the coolant pump is correctly seated to the engine block before installing and tightening the fasteners, or damage to the coolant pump may occur. Remove the 3 bolts and the coolant pump. - Remove and discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). 6. To install, reverse the removal procedure. - Lubricate the O-ring seal with clean engine coolant. 7. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalytic Converter Mounting Gasket > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter Mounting Gasket: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Catalytic Converter Mounting Gasket: Customer Interest Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalytic Converter Mounting Gasket > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter Mounting Gasket: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2021 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalytic Converter Mounting Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter Mounting Gasket: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Catalytic Converter Mounting Gasket: All Technical Service Bulletins Engine Controls/Exhaust MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalytic Converter Mounting Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter Mounting Gasket: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2027 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Manifold: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust MIL ON/DTCs P013A/P0130/P0400 Exhaust Manifold: Customer Interest Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Manifold: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust MIL ON/DTCs P013A/P0130/P0400 > Page 2036 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Manifold: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Exhaust Manifold: All Technical Service Bulletins Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Manifold: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2042 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Page 2043 Exhaust Manifold: Specifications Install 7 new exhaust manifold studs in the cylinder head. Tighten to.................................................. ..................................................................................................................................................17 Nm (150 lb-in). Position the catalytic converter and tighten the 7 new nuts in the sequence shown in 2 stages: Stage 1: Tighten to............................................................................................................................... ..........................................................48 Nm (35 lb-ft). Stage 2: Tighten to.......................................... ...............................................................................................................................................48 Nm (35 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Page 2044 Exhaust Manifold: Service and Repair Exhaust Manifold Cleaning and Inspection 1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket sealing surfaces. 2. NOTE: New exhaust manifold gaskets, studs, nuts and/or bolts must be installed when an exhaust manifold is serviced. NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot of length, such as Snap-On(R) GA438A or equivalent. For example, if the Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end. Using the Straightedge and a Feeler Gauge Set, check the exhaust manifold sealing surface for warpage. If the warpage is greater than 0.76 mm (0.0299 in), install a new exhaust manifold. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Downpipe Exhaust Pipe: Service and Repair Exhaust Downpipe Exhaust Downpipe - 2.5L Removal and Installation 1. With the vehicle in NEUTRAL, Position it on a hoist. 2. Remove the exhaust intermediate pipe. For additional information, refer to Exhaust Intermediate Pipe - 2.5L, Hybrid See: Exhaust Intermediate Pipe. 3. Remove the 2 exhaust bracket bolts. - To install, tighten to 25 Nm (18 lb-ft). 4. Remove the 2 exhaust downpipe-to-exhaust manifold nuts and the exhaust downpipe. - To install, tighten to 40 Nm (30 lb-ft). 5. To install, reverse the removal procedure. - Install new gaskets and nuts. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Downpipe > Page 2049 Exhaust Pipe: Service and Repair Exhaust System - Exploded View Exhaust System - Exploded View 2.5L 3.0L (View 1 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Downpipe > Page 2050 3.0L (View 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Downpipe > Page 2051 2.5L Hybrid Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Downpipe > Page 2052 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Downpipe > Page 2053 Exhaust Pipe: Service and Repair Exhaust Intermediate Pipe Exhaust Intermediate Pipe - 2.5L, Hybrid Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2.5L 2. Remove and discard the 3 exhaust intermediate pipe-to-exhaust downpipe nuts. 2.5L Hybrid 3. Remove and discard the 3 exhaust intermediate pipe-to-catalytic converter manifold nuts. All vehicles 4. NOTICE: Only use hand tools when removing or installing the spring nuts or damage may occur to the exhaust intermediate pipe flange studs. NOTE: When loosening the exhaust intermediate pipe spring nuts, alternately loosen the nuts from side to side. Remove and discard the two 10-mm catalytic converter-to-exhaust intermediate pipe spring nuts and remove the intermediate pipe. Installation All vehicles 1. Inspect the exhaust intermediate pipe flange studs for damage. - If damaged, replace stud(s), or if stud comes out when removing nut(s), replace the stud(s). 2. If replacing the exhaust intermediate pipe flange stud(s), use the C-Frame and Screw Installer/Remover to push the 10-mm stud out of the flange. 3. NOTE: When positioning the new 10-mm stud in the exhaust intermediate flange, make sure to line up the new stud seat knurls with witness knurl grooves in the exhaust intermediate flange. If replacing the exhaust intermediate pipe flange stud(s), use a C-clamp and a deep well socket to push the 10-mm stud fully into the flange. - Make sure the stud is fully and evenly seated into the flange. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Downpipe > Page 2054 4. NOTICE: Replace the gasket by hand. Do not rotate the gasket back and forth during installation. Doing so may lessen the gaskets ability to seal and stay correctly positioned during assembly. NOTE: Thoroughly clean the sealing surfaces of the flanges using a finishing pad. Inspect the cleaned sealing surface for nicks and scratches and replace as necessary. Install a new converter-to-exhaust intermediate pipe gasket by hand. 5. Install the 2 new 10-mm catalytic converter-to-exhaust intermediate pipe spring nuts and alternately tighten RH side to LH side in sequence in 3 stages: Stage 1: Tighten to 5 Nm (44 lb-in). - Stage 2: Tighten to 15 Nm (133 lb-in). - Stage 3: Tighten to 25 Nm (18 lb-ft). 2.5L Hybrid 6. Install 3 new exhaust intermediate pipe-to-catalytic converter manifold nuts. - Tighten to 25 Nm (18 lb-ft). 2.5L 7. Install 3 new exhaust intermediate pipe-to-exhaust downpipe nuts. - Tighten to 25 Nm (18 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 11-2-19 > Feb > 11 > Drivetrain/Exhaust - Highway Speed Rumble/Vibration Exhaust Pipe/Muffler Hanger: Customer Interest Drivetrain/Exhaust - Highway Speed Rumble/Vibration TSB 11-2-19 02/28/11 AWD - COLD TEMPERATURES - VIBRATION AT HIGHWAY SPEEDS AND/OR VIBRATION/RUMBLE/EXCESSIVE EXHAUST NOISE AFTER A COLD START - BUILT ON OR BEFORE 6/13/2010 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 10-16-2 to add a production fix date, update the Issue Statement Service Procedure and Part List. ISSUE Some 2009-2010 Escape and Mariner AWD vehicles built on or before 6/13/2010 may exhibit a highway speed vibration that is isolated to the rear driveshaft and/or a vibration/rumble/excessive exhaust type noise when in ambient temperatures of approximately -26 degrees Celsius (-15 degrees Fahrenheit) or lower. The vibration and/or noise will eventually diminish once vehicle reaches normal operating temperature. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE Vehicles exhibiting a vibration/rumble/excessive exhaust type noise, proceed to Step 1. For vehicles with a highway speed driveshaft vibration only, skip to Step 2. 1. Replace all five (5) exhaust hangers. Refer to WSM, Section 309-00. 2. Replace the rear driveshaft center bearing assembly. Refer to Instruction Sheet included in the kit, and Workshop Manual (WSM), Section 205-01. Parts Block 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 110219A 2009-2010 Escape And 0.3 Hr. Mariner AWD: Replace All Five (5) Exhaust Hangers (Do Not Use With Any Other Labor Operations) 110219B 2009-2010 Escape And 1.0 Hr. Mariner AWD: Replace The Rear Driveshaft Center Bearing Assembly (Do Not Use With Any Other Labor Operations) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 11-2-19 > Feb > 11 > Drivetrain/Exhaust - Highway Speed Rumble/Vibration > Page 2063 110219C 2009-2010 Escape And 1.1 Hrs. Mariner AWD: Replace The Rear Driveshaft Center Bearing Assembly And Replace All Five (5) Exhaust Hangers (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 4R602 D4 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 11-2-19 > Feb > 11 > Drivetrain/Exhaust - Highway Speed Rumble/Vibration Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Drivetrain/Exhaust - Highway Speed Rumble/Vibration TSB 11-2-19 02/28/11 AWD - COLD TEMPERATURES - VIBRATION AT HIGHWAY SPEEDS AND/OR VIBRATION/RUMBLE/EXCESSIVE EXHAUST NOISE AFTER A COLD START - BUILT ON OR BEFORE 6/13/2010 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 10-16-2 to add a production fix date, update the Issue Statement Service Procedure and Part List. ISSUE Some 2009-2010 Escape and Mariner AWD vehicles built on or before 6/13/2010 may exhibit a highway speed vibration that is isolated to the rear driveshaft and/or a vibration/rumble/excessive exhaust type noise when in ambient temperatures of approximately -26 degrees Celsius (-15 degrees Fahrenheit) or lower. The vibration and/or noise will eventually diminish once vehicle reaches normal operating temperature. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE Vehicles exhibiting a vibration/rumble/excessive exhaust type noise, proceed to Step 1. For vehicles with a highway speed driveshaft vibration only, skip to Step 2. 1. Replace all five (5) exhaust hangers. Refer to WSM, Section 309-00. 2. Replace the rear driveshaft center bearing assembly. Refer to Instruction Sheet included in the kit, and Workshop Manual (WSM), Section 205-01. Parts Block 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 110219A 2009-2010 Escape And 0.3 Hr. Mariner AWD: Replace All Five (5) Exhaust Hangers (Do Not Use With Any Other Labor Operations) 110219B 2009-2010 Escape And 1.0 Hr. Mariner AWD: Replace The Rear Driveshaft Center Bearing Assembly (Do Not Use With Any Other Labor Operations) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 11-2-19 > Feb > 11 > Drivetrain/Exhaust - Highway Speed Rumble/Vibration > Page 2069 110219C 2009-2010 Escape And 1.1 Hrs. Mariner AWD: Replace The Rear Driveshaft Center Bearing Assembly And Replace All Five (5) Exhaust Hangers (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 4R602 D4 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust System - Exploded View Muffler: Service and Repair Exhaust System - Exploded View Exhaust System - Exploded View 2.5L 3.0L (View 1 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2074 3.0L (View 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2075 2.5L Hybrid Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2076 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2077 Muffler: Service and Repair Muffler Muffler Removal and Installation 1. NOTE: The production catalytic converter and muffler assembly is a one piece construction. The service catalytic converter and muffler is a 2-piece construction. NOTE: If replacement is not required, the production catalytic converter and muffler assembly can be removed and installed as one piece. It is only necessary to cut the production exhaust to enable the service section to be fitted. Before cutting any part of the exhaust system, check that the position of the cut is correct in comparison to the service section being installed. The muffler and catalytic converter are serviced together. For additional information, refer to Catalytic Converter - Underbody See: Catalytic Converter/Service and Repair/Catalytic Converter Underbody. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Resonator > Component Information > Service and Repair Exhaust Resonator: Service and Repair Resonator Removal NOTICE: Do not use oil or grease-based lubricants on the insulators. They may cause deterioration of the rubber. NOTICE: Oil or grease-based lubricants on the insulators may cause the exhaust hanger insulator to separate from the exhaust hanger bracket during vehicle operation. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTICE: Only use hand tools when removing or installing the spring nuts or damage may occur to the resonator flange studs. NOTE: When loosening the resonator spring nuts, alternately loosen the nuts from side to side. Remove and discard the two 8-mm resonator spring nuts. 3. NOTICE: Remove the resonator-to-muffler gasket by simultaneously pulling up and twisting the gasket off the pipe. Do not pry under the gasket or damage to the flange may occur. Detach the 2 resonator exhaust hangers and remove the resonator. - Discard the gasket. Installation 1. Inspect the resonator flange studs for damage. - If damaged, replace stud(s), or if stud comes out when removing nut(s), replace the stud(s). 2. If replacing the resonator flange stud(s), use the C-Frame and Screw Installer/Remover to push the 8-mm stud(s) out of the flange. 3. NOTE: When positioning the new 8-mm stud in the resonator flange, make sure to line up the new stud seat knurls with witness knurl grooves in the resonator flange. If replacing the resonator flange stud(s), use a C-clamp and a deep well socket to push the 8-mm stud fully into the flange. - Make sure the stud is fully and evenly seated into the flange. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Resonator > Component Information > Service and Repair > Page 2081 4. NOTICE: Replace the gasket by hand. Do not rotate the gasket back and forth during installation. Doing so may lessen the gaskets ability to seal and stay correctly positioned during assembly. NOTE: Thoroughly clean the sealing surfaces of the flanges using a finishing pad. Inspect the cleaned sealing surface for nicks and scratches and replace as necessary. Install a new resonator-to-muffler gasket. 5. Install the resonator and attach the 2 resonator exhaust hangers. 6. Install the 2 new 8-mm resonator-to-muffler spring nuts and alternately tighten RH side to LH side in sequence in 3 stages: - Stage 1: Tighten to 5 Nm (44 lb-in). - Stage 2: Tighten to 10 Nm (89 lb-in). - Stage 3: Tighten to 17 Nm (150 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Catalytic Converter Mounting Gasket > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter Mounting Gasket: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Catalytic Converter Mounting Gasket: Customer Interest Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Catalytic Converter Mounting Gasket > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter Mounting Gasket: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2091 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Catalytic Converter Mounting Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter Mounting Gasket: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Catalytic Converter Mounting Gasket: All Technical Service Bulletins Engine Controls/Exhaust MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Catalytic Converter Mounting Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter Mounting Gasket: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2097 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Service and Repair > High-Voltage Traction Battery Battery, Hybrid Drive: Service and Repair High-Voltage Traction Battery High-Voltage Traction Battery Removal and Installation WARNING: When servicing the high-voltage system, establish a buffer zone per the specified procedure. Failure to follow this instruction may result in serious personal injury or death. WARNING: Depower the high-voltage traction battery (HVTB) before carrying out any removal or installation procedures affecting the high-voltage battery system. Failure to follow this instruction may result in serious personal injury or death. WARNING: Wear high-voltage insulated safety gloves and a face shield when working with high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate safety and protection rating. Inspect the gloves before use and always wear them with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to follow these instructions may result in serious personal injury or death. WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious personal injury or death. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Service and Repair > High-Voltage Traction Battery > Page 2104 NOTE: A replacement High Voltage Traction Battery (HVTB) may have a low state of charge that is insufficient to start the vehicle. If this occurs, follow the instructions for the jump start procedure in the Owner's Literature. 1. Depower the HVTB. For additional information, refer to High-Voltage Traction Battery Systems Depowering See: Service and Repair/High-Voltage Traction Battery Systems Depowering. 2. Remove the rear cargo area carpet insert. 3. NOTE: When installing, tighten the screws on the HVTB first or an airflow loss to the HVTB may occur. Remove the 5 A/C return duct assembly screws. To install, tighten to 2 Nm (18 lb-in). 4. Remove the A/C return duct assembly. 5. NOTE: Due to clearance issues, the 40-pin connector must be disconnected last during the removal process and connected first during the installation process. Loosen the bolt and disconnect the 40-pin low voltage connector. - To install, tighten to 5 Nm (44 lb-in). 6. From the right rear door opening, fold the right rear seat cushion forward and remove the 2 high-voltage cables shield nuts (access the shield nuts through the slotted opening in the carpet). To install, tighten to 9 Nm (80 lb-in). 7. Fold the right rear seat backrest down and remove the high-voltage cables shield bolt, then remove the scrivet. - To install, tighten to 9 Nm (80 lb-in). 8. Remove the high-voltage cables shield. 9. Press the locking tab down and rotate the locking lever upward until the aligning dowels are disengaged from the locking lever to remove the high-voltage cables electrical connector. 10. NOTE: The attaching bolts have a conductive coating on them and are serrated under the head flange. These features ground the HVTB to the vehicle, which is required for electro-magnetic compatibility. If a bolt(s) is lost or damaged, a new bolt(s) must be installed with the identical type of bolt. Remove the 9 HVTB bolts. NOTE: Hand-start all of the bolts before tightening them to specification. To install, tighten to 55 Nm (41 lb-ft). 11. NOTE: Make certain to reinstall this plug during the HVTB installation procedure to avoid NVH issues. Remove the cap plug to expose the center (rear) lifting attachment point. 12. Attach 3 M10 x 1.5 x 35 eyebolts to the 3 HVTB lift points. Install nuts onto the eye bolts to gain the proper eyebolt height. Obtain the eyebolts Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Service and Repair > High-Voltage Traction Battery > Page 2105 locally. 13. NOTICE: Use chain lengths as specified. Changing the chain length may result in damage to the High Voltage Traction Battery (HVTB) or HVTB lifting points. Attach the lengths of chain to the eyebolts and the lifting device. 14. NOTICE: Make certain the High Voltage Traction Battery (HVTB) does not mar or damage the interior panels during removal. There is only 6 mm (0.23 in) clearance on each side. With an assistant, lift the HVTB off the 2 alignment dowels using a floor crane. 15. NOTE: Do not strike the headliner with the HVTB (or floor crane) during removal. Cover the battery mounting brackets with protective padding and remove the HVTB from the vehicle. 16. Inspect the HVTB tray drain grommet located in the floor pan underneath the HVTB. Replace if necessary. 17. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Service and Repair > High-Voltage Traction Battery > Page 2106 Battery, Hybrid Drive: Service and Repair High Voltage Traction Battery - 12 Volt Battery 12 Volt Battery Removal and Installation WARNING: Batteries contain sulfuric acid and produce explosive gases. Work in a well-ventilated area. Do not allow the battery to come in contact with flames, sparks or burning substances. Avoid contact with skin, eyes or clothing. Shield eyes when working near the battery to protect against possible splashing of acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes, then get prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow these instructions may result in serious personal injury. WARNING: Always lift a plastic-cased battery with a battery carrier or with hands on opposite corners. Excessive pressure on the battery end walls may cause acid to flow through the vent caps, resulting in personal injury and/or damage to the vehicle or battery. 1. Disconnect the 12-volt battery. 2. Remove the Air Cleaner (ACL) assembly. 3. Remove the battery wedge clamp and bolt. - To install, tighten to 9 Nm (80 lb-in). 4. Remove the battery. 5. Remove the 4 bolts and the battery tray. - To install, tighten to 9 Nm (80 lb-in). 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Cooling Fan, Hybrid Drive > Battery Cooling Fan Module, Hybrid Drive > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Cooling Fan, Hybrid Drive > Battery Cooling Fan Module, Hybrid Drive > Component Information > Locations > Page 2111 Battery Cooling Fan Module: Diagrams Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Cooling Fan, Hybrid Drive > Battery Cooling Fan Module, Hybrid Drive > Component Information > Locations > Page 2112 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Hybrid Battery Bus / Cable > Component Information > Service and Repair Hybrid Battery Bus / Cable: Service and Repair High-Voltage Cables Removal and Installation WARNING: When servicing the high-voltage system, establish a buffer zone per the specified procedure. Failure to follow this instruction may result in serious personal injury or death. WARNING: Depower the high-voltage traction battery (HVTB) before carrying out any removal or installation procedures affecting the high-voltage battery system. Failure to follow this instruction may result in serious personal injury or death. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Hybrid Battery Bus / Cable > Component Information > Service and Repair > Page 2116 WARNING: Wear high-voltage insulated safety gloves and a face shield when working with high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate safety and protection rating. Inspect the gloves before use and always wear them with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to follow these instructions may result in serious personal injury or death. WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious personal injury or death. 1. Depower the High Voltage Traction Battery (HVTB). For additional information, refer to High-Voltage Traction Battery Systems Depowering See: Service and Repair/High-Voltage Traction Battery Systems Depowering. 2. From the right rear door opening, fold the right rear seat cushion forward and remove the 2 high-voltage cables shield nuts (access the shield nuts through the slotted opening in the carpet). To install, tighten to 9 Nm (80 lb-in). 3. Fold the right rear seat backrest down and remove the high-voltage cables shield bolt. - To install, tighten to 9 Nm (80 lb-in). 4. Remove the high-voltage cables shield plastic rivet/screw. 5. Remove the high-voltage cables shield. 6. Press the locking tab down and rotate the locking lever upward until the aligning dowels are disengaged from the locking lever to remove the high-voltage cables electrical connector. 7. With the vehicle in NEUTRAL, position it on a hoist. 8. Remove the high-voltage cables floorpan grommet. 9. Remove the 2 bolts and the park brake cable bracket. - To install, tighten to 8 Nm (71 lb-in). 10. Remove the 4 bolts and the exhaust heat shield. - To install, tighten to 11 Nm (97 lb-in). 11. Remove the bolt and position the engine ground strap aside. - To install, tighten to 25 Nm (18 lb-ft). 12. Remove the 5 high-voltage cables conduit nuts (right side inner frame rail and floorpan). - To install, tighten to 8 Nm (71 lb-in). 13. Lower the vehicle. 14. Remove the 2 high-voltage cables bracket nuts (bulkhead). (Access the nuts through the engine compartment.) - To install, tighten to 8 Nm (71 lb-in). 15. Remove the nut and the eCVT shift cable. - To install, tighten to 8 Nm (71 lb-in). 16. Remove the high-voltage cables to the eCVT bolt. - To install, tighten to 9 Nm (80 lb-in). 17. Rotate the locking lever rearward until the alignment dowels are disengaged from the locking lever and remove the high-voltage cables connection to the eCVT. 18. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Hybrid Battery Service Switch > Component Information > Locations Hybrid Battery Service Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Hybrid Battery Service Switch > Component Information > Locations > Page 2120 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Converter, Hybrid Drive > Component Information > Service and Repair > Direct Current/Direct Current (DC/DC) Converter Voltage Converter: Service and Repair Direct Current/Direct Current (DC/DC) Converter Direct Current/Direct Current (DC/DC) Converter Removal and Installation WARNING: When servicing the high-voltage system, establish a buffer zone per the specified procedure. Failure to follow this instruction may result in serious personal injury or death. WARNING: Depower the high-voltage traction battery (HVTB) before carrying out any removal or installation procedures affecting the high-voltage battery system. Failure to follow this instruction may result in serious personal injury or death. WARNING: Wear high-voltage insulated safety gloves and a face shield when working with high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate safety and protection rating. Inspect the gloves before use and always wear them with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to follow these instructions may result in serious personal injury or death. WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious personal injury or death. 1. Depower the High Voltage Traction Battery (HVTB). For additional information, refer to Hybrid Drive Systems. 2. Disconnect the 12-volt battery. 3. Remove the degas bottle. 4. Disconnect the 2 female pin-type retainers from the DC/DC converter bracket. 5. NOTE: Press the locking clip to release the connector. Disconnect the DC/DC converter high voltage connector. 6. Clamp the Motor Electronics Cooling System (MECS) hoses to prevent coolant from leaking from the hoses during the repair. 7. Loosen the hose clamps and remove the MECS hoses from the DC/DC converter. 8. WARNING: Always tighten the DC/DC converter low-voltage battery cable fasteners to specification. Loose connections may result in Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Converter, Hybrid Drive > Component Information > Service and Repair > Direct Current/Direct Current (DC/DC) Converter > Page 2126 electrical arcing, which increases both the risk of fires and serious personal injury. Remove the 2 DC/DC converter low voltage battery cable nuts and remove the low voltage battery cables. To install, tighten to 12 Nm (106 lb-in). 9. Disconnect the DC/DC converter low voltage electrical connector. 10. Remove the 3 DC/DC converter nuts. - To install, tighten to 12 Nm (106 lb-in). 11. Remove the DC/DC converter assembly. 12. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Converter, Hybrid Drive > Component Information > Service and Repair > Direct Current/Direct Current (DC/DC) Converter > Page 2127 Voltage Converter: Service and Repair Direct Current/Direct Current (DC/DC) Converter Wiring Harness Direct Current/Direct Current (DC/DC) Converter Wiring Harness Removal and Installation WARNING: When servicing the high-voltage system, establish a buffer zone per the specified procedure. Failure to follow this instruction may result in serious personal injury or death. WARNING: Depower the high-voltage traction battery (HVTB) before carrying out any removal or installation procedures affecting the high-voltage battery system. Failure to follow this instruction may result in serious personal injury or death. WARNING: Wear high-voltage insulated safety gloves and a face shield when working with high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate safety and protection rating. Inspect the gloves before use and always wear them with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to follow these instructions may result in serious personal injury or death. WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious personal injury or death. 1. Depower the High Voltage Traction Battery (HVTB). For additional information, refer to Hybrid Drive Systems. 2. Disconnect the 12-volt battery. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Converter, Hybrid Drive > Component Information > Service and Repair > Direct Current/Direct Current (DC/DC) Converter > Page 2128 3. Remove the engine cover. 4. Disconnect the DC/DC converter harness connector from the Electronically Controlled Continuously Variable Transmission (eCVT). 5. Remove the degas bottle. 6. Disconnect the plastic loop. 7. Disconnect the 2 pin-type retainers. 8. Disconnect the 2 female pin-type retainers. 9. NOTE: Press the locking clip to release the connector. Disconnect the DC/DC converter high voltage electrical connector. 10. Remove the DC/DC converter wiring harness. 11. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Locations > DC/AC Inverter Module Voltage Converter Module: Locations DC/AC Inverter Module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Locations > DC/AC Inverter Module > Page 2133 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Locations > DC/AC Inverter Module > Page 2134 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Diagrams > DC/AC Inverter Module Voltage Converter Module: Diagrams DC/AC Inverter Module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Diagrams > DC/AC Inverter Module > Page 2137 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Diagrams > DC/AC Inverter Module > Page 2138 Voltage Converter Module: Diagrams DC/DC Converter Module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Diagrams > DC/AC Inverter Module > Page 2139 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Diagrams > DC/AC Inverter Module > Page 2140 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Diagrams > Page 2141 Voltage Converter Module: Description and Operation DC/DC Enable (DCE) The DCE is an output from the PCM to the DC/DC converter. The PCM enables the DC/DC converter after the PCM receives a contactors closed message and no error messages. The DCE circuit is high (the low side driver is off) when the DC/DC is commanded on. When the DCE low side driver is activated, the DC/DC converter is commanded off. For additional information on DCE, refer to the DC/DC converter description in Hybrid Electric Control Hardware See: Powertrain Management/Computers and Control Systems/Description and Operation/Hybrid Electric Control Hardware. DC/DC Fault The DC/DC fault (DCF) signal is an input to the PCM from the DC/DC converter. This signal is low under normal conditions and switches high when a concern exists within the DC/DC converter cooling system, the high voltage power supply to the DC/DC converter, or the low voltage output system. The PCM disables or limits the operation of the DC/DC converter by the DC/DC enable circuit (DCE), when a DCF concern is indicated. For additional information on DCF, refer to the DC/DC converter description in Hybrid Electric Control Hardware See: Powertrain Management/Computers and Control Systems/Description and Operation/Hybrid Electric Control Hardware. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Description and Operation Voltage Inverter: Description and Operation Generator Shut Down (GSDN) The PCM keeps the generator motor inverter enabled by continuously toggling the generator motor shut down (GMSDN) output. Typical output frequency varies between 49 and 75 Hz at 50% duty cycle. The PCM also broadcasts a redundant not shutdown message to the TCM over the communication link. When a concern condition is detected, the PCM stops generating this frequency signal and broadcasts a shutdown message to the TCM over the communication link. The TCM then disables the generator motor inverter and sets an appropriate DTC. In the event of GMSDN circuit failure, the PCM still broadcasts a not shutdown message but the hard wire signal frequency is out of expected range. If the circuit becomes open, the vehicle shutdowns and the TCM sets the appropriate DTC. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Battery Cooling Fan Module, Hybrid Drive > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Battery Cooling Fan Module, Hybrid Drive > Component Information > Locations > Page 2149 Battery Cooling Fan Module: Diagrams Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Battery Cooling Fan Module, Hybrid Drive > Component Information > Locations > Page 2150 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Locations > DC/AC Inverter Module Voltage Converter Module: Locations DC/AC Inverter Module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Locations > DC/AC Inverter Module > Page 2155 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Locations > DC/AC Inverter Module > Page 2156 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Diagrams > DC/AC Inverter Module Voltage Converter Module: Diagrams DC/AC Inverter Module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Diagrams > DC/AC Inverter Module > Page 2159 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Diagrams > DC/AC Inverter Module > Page 2160 Voltage Converter Module: Diagrams DC/DC Converter Module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Diagrams > DC/AC Inverter Module > Page 2161 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Diagrams > DC/AC Inverter Module > Page 2162 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Voltage Converter Module, Hybrid Drive > Component Information > Diagrams > Page 2163 Voltage Converter Module: Description and Operation DC/DC Enable (DCE) The DCE is an output from the PCM to the DC/DC converter. The PCM enables the DC/DC converter after the PCM receives a contactors closed message and no error messages. The DCE circuit is high (the low side driver is off) when the DC/DC is commanded on. When the DCE low side driver is activated, the DC/DC converter is commanded off. For additional information on DCE, refer to the DC/DC converter description in Hybrid Electric Control Hardware See: Powertrain Management/Computers and Control Systems/Description and Operation/Hybrid Electric Control Hardware. DC/DC Fault The DC/DC fault (DCF) signal is an input to the PCM from the DC/DC converter. This signal is low under normal conditions and switches high when a concern exists within the DC/DC converter cooling system, the high voltage power supply to the DC/DC converter, or the low voltage output system. The PCM disables or limits the operation of the DC/DC converter by the DC/DC enable circuit (DCE), when a DCF concern is indicated. For additional information on DCF, refer to the DC/DC converter description in Hybrid Electric Control Hardware See: Powertrain Management/Computers and Control Systems/Description and Operation/Hybrid Electric Control Hardware. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Hybrid Battery Service Switch > Component Information > Locations Hybrid Battery Service Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Hybrid Battery Service Switch > Component Information > Locations > Page 2168 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Hybrid Drive Coolant Temperature Sensor > Component Information > Description and Operation Hybrid Drive Coolant Temperature Sensor: Description and Operation Motor Electronics Coolant Temperature (MECT) Sensor The MECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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. A thermistor type sensor is considered a passive sensor. 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 MECT provides motor electronics cooling system temperature information to the PCM. The PCM uses this information for determining when to activate the cooling system fans and indicate over-temperature. Typical Thread Type Sensor Motor Electronics Coolant Temperature (MECT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation Torque-Based Electronic Throttle Control (ETC) Overview The torque-based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. Electronic Throttle Body (ETB) The ETB has the following characteristics: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires two wires). - An internal spring is used to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore. This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. - The required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. - There is one reference voltage and one signal return circuit between the PCM and the ETB. The reference voltage and the signal return circuits are shared with the reference voltage and signal return circuits used by the accelerator pedal position (APP) sensor. There are also two throttle position (TP) signal circuits for redundancy. The redundant TP signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor For additional information on the APP sensor, refer to Engine Control Components See: Computers and Control Systems/Description and Operation/Engine Control Components. Electronic Throttle Control (ETC) System Strategy The torque-based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize the fuel control while delivering the requested torque. The ETC monitor system is distributed across two processors within the PCM: the main powertrain control processor unit (CPU) and a separate monitoring processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, appropriate corrective action is taken. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2178 ECT System Failure Mode Effects Management (FMEM) Electronic Throttle Monitor Operation a Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Accelerator Pedal Position (APP) and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check a Correlation and range/performance - sensor disagreement between processors internal to the PCM. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions for additional DTC information. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2179 Throttle Position (TP) Sensor Check a Correlation and range/performance - sensor disagreement between processors internal to the PCM, TP inconsistent with requested throttle plate position. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions for additional DTC information. Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check a Note: For all DTCs, in addition to the MIL, the powertrain malfunction indicator (wrench) is on for the concern that caused the FMEM action. Monitor execution is continuous. Monitor false detection duration is less than 5 seconds to register a concern. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Engine Control Module: Customer Interest Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2188 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0442/P0456/P1450 TSB 10-1-3 02/01/10 HYBRID ONLY - DTCS P0442, P0456 OR P1450 - BUILT ON OR BEFORE 4/6/2009 FORD: 2010 Fusion 2009 Escape MERCURY: 2010 Milan 2009 Mariner This article supersedes TSB 09-9-9 to add a production fix date. ISSUE Some 2009 Escape Hybrid, Mariner Hybrid, 2010 Fusion Hybrid and Milan Hybrid vehicles built on or before 4/6/2009 may exhibit a malfunction indicator light (MIL) accompanied by diagnostic trouble code (DTC) P0442, P0456 or P1450. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Follow the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostic procedures for any DTC code that may be present to ensure the Evaporative Emissions (EVAP) system is functioning properly. 2. When performing EVAP diagnostics on Escape Hybrid and Mariner Hybrid vehicles, the ambient temperature must be greater than 32 °F (0 °C) and the heating ventilation air conditioning (HVAC) system should be set to Defrost. This will provide continuous gasoline engine operation. 3. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 60.11 and higher or 61.01 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 100103A 2010 Fusion Hybrid/Milan 0.3 Hr. Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) 100103A 2009 Escape 0.3 Hr. Hybrid/Mariner Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 2193 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Engine Control Module: All Technical Service Bulletins Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2199 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0442/P0456/P1450 TSB 10-1-3 02/01/10 HYBRID ONLY - DTCS P0442, P0456 OR P1450 - BUILT ON OR BEFORE 4/6/2009 FORD: 2010 Fusion 2009 Escape MERCURY: 2010 Milan 2009 Mariner This article supersedes TSB 09-9-9 to add a production fix date. ISSUE Some 2009 Escape Hybrid, Mariner Hybrid, 2010 Fusion Hybrid and Milan Hybrid vehicles built on or before 4/6/2009 may exhibit a malfunction indicator light (MIL) accompanied by diagnostic trouble code (DTC) P0442, P0456 or P1450. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Follow the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostic procedures for any DTC code that may be present to ensure the Evaporative Emissions (EVAP) system is functioning properly. 2. When performing EVAP diagnostics on Escape Hybrid and Mariner Hybrid vehicles, the ambient temperature must be greater than 32 °F (0 °C) and the heating ventilation air conditioning (HVAC) system should be set to Defrost. This will provide continuous gasoline engine operation. 3. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 60.11 and higher or 61.01 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 100103A 2010 Fusion Hybrid/Milan 0.3 Hr. Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) 100103A 2009 Escape 0.3 Hr. Hybrid/Mariner Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 2204 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2205 Engine Control Module: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2206 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2207 Engine Control Module: Diagrams Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2208 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2209 Part 3 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2210 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2211 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2212 Part 3 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2213 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2214 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory (EEPROM) WARNING: THIS VEHICLE IS EQUIPPED WITH HIGH VOLTAGE CABLES, COMPONENTS, AND WIRING. THE HIGH VOLTAGE WARNING LABELS CONTAINING THE HIGH VOLTAGE SYMBOL ARE LOCATED ON EACH HIGH VOLTAGE COMPONENT. HIGH VOLTAGE CABLES AND WIRING ARE ORANGE IN COLOR. CERTIFIED RUBBER INSULATING GLOVES AND A FACE SHIELD MUST BE WORN WHEN WORKING WITH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING. THE IGNITION KEY MUST BE CYCLED TO THE OFF POSITION FOR A MINIMUM OF 5 MINUTES, AND THE HIGH VOLTAGE TRACTION BATTERY SERVICE DISCONNECT PLUG PLACED IN THE SERVICING/SHIPPING POSITION BEFORE DISCONNECTING THE HIGH VOLTAGE CABLES. DO NOT DISCONNECT, DISABLE, OR TOUCH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING DURING THE MODULE REPROGRAMMING PROCEDURE BECAUSE HIGH VOLTAGE IS PRESENT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH. Description Flash electrically erasable programmable read only memory (EEPROM) is contained in an integrated circuit internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block must be programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate diagnostic trouble code (DTC) P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. Failure to carry out this procedure correctly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, and the presence of speed control. Only items applicable to vehicle hardware and supported by the VID block are displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. On selected vehicles equipped with permanent DTC reporting capabilities, neutral profile correction should be learned after a PCM replacement in order to activate the misfire monitor. This can be accomplished using the Misfire Monitor Neutral Profile Learn function on the scan tool. Reprogramming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the manufacturer's user manual for details. Programming the VID Block for a Replacement PCM The VID block on a replacement PCM is blank and requires programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it is replaced. Manual data entry must be carried out if the old module is damaged and is incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the Module/Parameter programming, referring to the manufacturer's user manual. Make certain that all parameters are included. Failure to correctly program tire size in revolutions per mile, (rev/mile = 63,360 divided by the tire circumference in inches) or axle ratio, may result in codes P1635 and P1639. You may be instructed to contact the As Built data center for the information needed to manually update the VID block with the scan tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury technicians, contact the National Hotline or Professional Technician Society (PTS) website for As Built data. Non-Ford technicians, use the Motorcraft website at Motorcraft.com. From the Motorcraft homepage, use the search function to find the Module Programming or As Built Data. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the scan tool. PCM Reprogramming Note: After the PCM is successfully reprogrammed, clear any TCM DTCs that may have been stored during reprogramming. At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2217 Engine Control Module: Removal and Replacement Powertrain Control Module (PCM) Removal 1. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation (PMI) procedure. See: Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 2. Detach the wiring harness retainer from the cowl stud bolt. 3. Disconnect the 3 PCM electrical connectors. 4. Remove the 2 bolts and the PCM. 5. Remove and inspect the PCM cowl seal. Install new if damaged. Installation 1. Install the PCM cowl seal. 2. Install the PCM and the 2 bolts. - Tighten to 8 Nm (71 lb-in). 3. Connect the 3 PCM electrical connectors. 4. Attach the wiring harness retainer to the cowl stud bolt. 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation (PMI) procedure. See: Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 2225 Fuel Pump Control Unit: Service and Repair Fuel Pump Control Module Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Fuel Pump (FP) control module electrical connector. 3. NOTICE: Do not overtighten the fasteners or damage will occur. Remove the 2 bolts and the FP control module. - To install, tighten to 5 Nm (44 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2234 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2235 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the powertrain control module (PCM) receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Accelerator Pedal Position (APP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2239 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2240 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. 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 volume of air 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. The MAF sensor is located between the air cleaner and the throttle body inside the air cleaner assembly. Mass Air Flow (MAF) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2241 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 screws and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2245 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2246 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The CMP sensor is a Hall-effect sensor that detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. The PCM also uses the CMP signal to select the correct ignition coil to fire. Typical Hall-effect CMP Sensor Camshaft Position (CMP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2247 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 3. NOTE: Lubricate the CMP sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2251 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2252 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates the 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. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between pulse wheel teeth. Typical Crankshaft Position (CKP) Sensor Crankshaft Position (CKP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2253 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts, the pin-type retainer (not shown) and the RH splash shield. 3. Turn the crankshaft clockwise until the hole in the crankshaft pulley is in the 3 o'clock position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2254 4. Remove the engine plug bolt. 5. NOTE: When the crankshaft contacts the Crankshaft TDC Timing Peg, the No. 1 cylinder will be at Top Dead Center (TDC). Install the Crankshaft TDC Timing Peg and turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg. 6. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 7. Remove the bolts and the CKP sensor. Installation 1. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6 mm x 18 mm bolt in the crankshaft pulley and thread it into the front cover. 2. Install the CKP sensor and the 2 bolts. - Do not tighten the bolts at this time. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2255 3. Adjust the CKP sensor with the Crankshaft Sensor Aligner. - Tighten the 2 CKP bolts to 7 Nm (62 lb-in). 4. Connect the CKP sensor electrical connector. 5. Remove the 6 mm x 18 mm bolt from the crankshaft pulley. 6. Install the engine plug bolt. - Tighten to 20 Nm (177 lb-in). 7. Install the RH splash shield, 5 bolts and the pin-type retainer (not shown). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2259 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2260 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which the resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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 varying the resistance of the passive sensor causes a variation in total current flow. The CHT sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor provides 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 then initiates 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 See: Computers and Control Systems/Description and Operation/Powertrain Control Software Fail-Safe Cooling Strategy. Cylinder Head Temperature (CHT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2261 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. Detach the Cylinder Head Temperature (CHT) sensor cover and position aside. 2. Disconnect the CHT sensor electrical connector. 3. Remove the CHT sensor. - To install, tighten to 12 Nm (106 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Level Sensor: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Fuel Tank Filler Pipe Assembly Fuel Tank and Fuel Pump (FP) module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2266 Fuel Tank Supports Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2267 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2268 Fuel Level Sensor: Service and Repair Fuel Pump Module Fuel Pump Module Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the Fuel Pump (FP) module access cover. 4. NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material. Disconnect the FP module electrical connector. 5. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage. Disconnect the fuel tube-to-FP module quick connect coupling. 6. Disconnect the fuel tank filler pipe recirculation tube-to-FP module quick connect coupling. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2269 7. NOTE: For initial fuel draining, it is required to remove the fuel through the fuel tank filler pipe recirculation tube port on the FP module. Connect the Fuel Storage Tanker to the fuel tank filler pipe recirculation tube port on the FP module and remove approximately one-fourth of the fuel (from a completely full tank), lowering the fuel level below the FP module mounting flange. 8. NOTICE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP module when removing the lock ring. NOTE: When installing the FP module, install a new O-ring seal. Install the Fuel Tank Sender Unit Wrench and remove the FP module lock ring. 9. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm. NOTE: Some residual fuel may remain in the FP module. Carefully drain into a suitable container. Completely remove the FP module from the fuel tank. 10. NOTE: Inspect the surfaces of the FP module flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded. NOTE: To install, apply clean engine oil to the O-ring seal. Remove and discard the FP module O-ring seal. 11. NOTE: Make sure to install a new FP module O-ring seal and lock ring. To install, reverse the removal procedure. Make sure the alignment arrows on the FP module and the fuel tank meet before tightening the FP module lock ring. - Tighten the FP lock ring until it meets the stop tabs on the fuel tank. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2270 Fuel Level Sensor: Service and Repair Fuel Level Sender Fuel Level Sender Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the Fuel Pump (FP) module. For additional information, refer to Fuel Pump Module See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Pump Module. 2. Disconnect the electrical connector, release the locking tabs and remove the fuel level sender from the FP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2271 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 2275 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor The FTP sensor is used to measure the fuel tank pressure. In-line Fuel Tank Pressure (FTP) Sensor Fuel Tank Pressure (FTP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2279 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2280 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The IAT sensor is integrated into the mass air flow (MAF) sensor. It is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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. A thermistor type sensor is considered a passive sensor. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in the 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 sensor provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, and ignition timing. Integrated Intake Air Temperature (IAT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2284 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2285 Knock Sensor: Description and Operation Knock Sensor (KS) The KS 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2286 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the intake manifold. 3. Remove the bolt and the Knock Sensor (KS). - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2290 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2291 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor uses a piezo-resistive silicon sensing element to provide a voltage proportional to the absolute pressure in the intake manifold. The MAP sensor is part of the EGR system. The PCM uses information from the MAP, TP, MAF, CHT and CKP sensors to determine how much exhaust gas is introduced into the intake manifold. Typical Manifold Absolute Pressure (MAP) Sensor Manifold Absolute Pressure (MAP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2292 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the Throttle Body (TB). 3. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector. 4. Using a tool like KD Tool #58181 or Lisle T25 Torx Bit, remove the screw and the MAP sensor. - To install, tighten to 3 Nm (27 lb-in). 5. NOTE: Lubricate the MAP sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Oxygen Sensor: Customer Interest Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2301 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Oxygen Sensor: All Technical Service Bulletins Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2307 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2310 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #12 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #12 > Page 2313 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2314 Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) The HO2S 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 voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a 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 a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Typical Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) Universal Heated Oxygen Sensor (HO2S) The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal HO2S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor Exploded View Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page 2317 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S. - Calculate the correct torque wrench setting for the following torque. - To install, tighten to 48 Nm (35 lb-ft). 4. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page 2318 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor Catalyst Monitor Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector. 3. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS. - Calculate the correct torque wrench setting for the following torque. - To install, tighten to 48 Nm (35 lb-ft). 4. NOTE: Apply a light coat of anti-seize lubricant to the threads of the CMS. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has two signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The two ETB throttle position sensor signals make sure the PCM receives a correct input even if one signal has a concern. There is one reference voltage circuit and one signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to the description of the Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. Electronic Throttle Body (ETB) Throttle Position Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2326 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2327 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the powertrain control module (PCM) receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Accelerator Pedal Position (APP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2331 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2332 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. 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 volume of air 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. The MAF sensor is located between the air cleaner and the throttle body inside the air cleaner assembly. Mass Air Flow (MAF) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2333 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 screws and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 2340 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 2341 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shut-off (IFS) Switch The IFS switch consists of a steel cone held in place by a magnet. When a sharp impact occurs, the cone breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner's Literature, Roadside Emergencies for the location of the IFS switch. Typical Inertia Fuel Shut-off (IFS) Switch Typical Inertia Fuel Shut-off (IFS) Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 2342 Inertia Fuel Shutoff Switch: Service and Repair Inertia Fuel Shutoff (IFS) Switch 1. Remove the RH lower A-pillar trim panel. 2. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 3. Remove the 2 bolts and the IFS switch. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has two signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The two ETB throttle position sensor signals make sure the PCM receives a correct input even if one signal has a concern. There is one reference voltage circuit and one signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to the description of the Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. Electronic Throttle Body (ETB) Throttle Position Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2350 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2351 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The CMP sensor is a Hall-effect sensor that detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. The PCM also uses the CMP signal to select the correct ignition coil to fire. Typical Hall-effect CMP Sensor Camshaft Position (CMP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2352 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 3. NOTE: Lubricate the CMP sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2356 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2357 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates the 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. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between pulse wheel teeth. Typical Crankshaft Position (CKP) Sensor Crankshaft Position (CKP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2358 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts, the pin-type retainer (not shown) and the RH splash shield. 3. Turn the crankshaft clockwise until the hole in the crankshaft pulley is in the 3 o'clock position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2359 4. Remove the engine plug bolt. 5. NOTE: When the crankshaft contacts the Crankshaft TDC Timing Peg, the No. 1 cylinder will be at Top Dead Center (TDC). Install the Crankshaft TDC Timing Peg and turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg. 6. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 7. Remove the bolts and the CKP sensor. Installation 1. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6 mm x 18 mm bolt in the crankshaft pulley and thread it into the front cover. 2. Install the CKP sensor and the 2 bolts. - Do not tighten the bolts at this time. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2360 3. Adjust the CKP sensor with the Crankshaft Sensor Aligner. - Tighten the 2 CKP bolts to 7 Nm (62 lb-in). 4. Connect the CKP sensor electrical connector. 5. Remove the 6 mm x 18 mm bolt from the crankshaft pulley. 6. Install the engine plug bolt. - Tighten to 20 Nm (177 lb-in). 7. Install the RH splash shield, 5 bolts and the pin-type retainer (not shown). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Removal and Installation NOTE: For non-functional ignition lock cylinders, the steering column lock module has to be replaced. 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2368 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2369 Knock Sensor: Description and Operation Knock Sensor (KS) The KS 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2370 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the intake manifold. 3. Remove the bolt and the Knock Sensor (KS). - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure Key ON Engine OFF (KOEO)............................................................................................................... .........................................................379 kPa (55 psi) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2375 Fuel Pressure: Testing and Inspection Fuel System Pressure Test WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. NOTE: Early build 3.0L engines are equipped with a Schrader valve on the fuel rail. Late build 3.0L engines do not have a Schrader valve. All vehicles 1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. For additional information, refer to Battery. Vehicles with 2.5L engine 3. Disconnect the fuel tube-to-fuel rail quick connect coupling. For additional information, refer to Quick Connect Coupling See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Quick Connect Coupling. 4. Install the Fuel Pressure Test Kit between the fuel tube and the fuel rail. Vehicles with early build 3.0L engine 5. Remove the fuel rail Schrader valve cap. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2376 6. Install the Fuel Pressure Test Kit to the fuel rail Schrader valve. Vehicles with late build 3.0L engine 7. Disconnect the fuel jumper tube-to-fuel tube quick connect coupling. For additional information, refer to Quick Connect Coupling See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Quick Connect Coupling. 8. Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel tube. All vehicles 9. NOTE: The Fuel Pump (FP) fuse was removed previously to release the fuel system pressure and must be installed to test the fuel system pressure. Install the FP fuse. 10. Connect the battery ground cable. For additional information, refer to Battery. 11. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 12. NOTE: Upon completion of the fuel system pressure test, open the drain valve on the Fuel Pressure Test Kit and release fuel system pressure and drain any residual fuel into a suitable container prior to removing the tool. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Measured/PID Values Hot Idle ................................................................................................................................................ ............................................................. 1072 RPM Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Intake Air System Components - Exploded View Air Cleaner (ACL) Assembly and Outlet Pipe Air Cleaner (ACL) Intake Pipe Intake Air Resonator Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2384 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel System Pressure Release WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. NOTE: The Fuel Pump (FP) fuse is located in the Battery Junction Box (BJB), location 22. Remove the FP fuse. 2. Start the engine and allow it to idle until it stalls. 3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released. 4. Turn the ignition switch to the OFF position. 5. When the fuel system service is complete, install the FP fuse. 6. NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for leaks prior to starting the engine. Start the vehicle and check the fuel system for leaks. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Firing Order Firing Order: Specifications Firing Order Firing Order.......................................................................................................................................... .........................................................................1-3-4-2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Firing Order > Page 2393 Firing Order: Specifications Engine Cylinder Identification Engine Engine Cylinder Identification Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark plug gap..................................................................................................................................... ....................................1.08-1.18 mm (0.042-0.046 in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 2398 Spark Plug: Specifications Torque Specifications Spark plugs........................................................................................................................................... ........................................................12 Nm (106 lb-in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2399 Spark Plug: Application and ID Spark plug............................................................................................................................................ .............................................................AYSF-32-YPC Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2400 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. - Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. - Install a new spark plug. 2. Check for oil fouling. - Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. - Correct the oil leak concern. - Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. Install new spark plugs. 4. Inspect for normal burning. - Check for light tan or gray deposits on the firing tip. 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. Install a new spark plug. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2401 6. Inspect for overheating, identified by white or light gray spots and with a bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. - Install new spark plugs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View Spark Plug: Service and Repair Engine Ignition Components - Exploded View Engine Ignition Components - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 2404 Spark Plug: Service and Repair Spark Plugs Spark Plugs Removal and Installation 1. Remove the ignition coils. For additional information, refer to Ignition Coil-On-Plug See: Ignition System/Ignition Coil/Service and Repair/Ignition Coil-On-Plug. 2. NOTICE: Only use hand tools when removing or installing the spark plugs, or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material in the spark plug well prior to removing the spark plugs. Remove the spark plugs. - To install, tighten to 12 Nm (106 lb-in). 3. Inspect the spark plugs. 4. To install, reverse the removal procedure. - Adjust the spark plug gap as necessary. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil meeting Ford specification on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are worn or damaged. 2. If compression does not improve, valves are sticking or not seating correctly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so the lowest reading is within 75% of the highest reading. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2408 Compression Check: Testing and Inspection Engine Component Tests The following component tests are used to diagnose engine concerns. Compression Test - Hybrid The compression test requires cranking the engine a minimum of 5 compression strokes with the throttle plate in the wide-open position for each cylinder. The engine cranking diagnostic mode must be used to crank the engine and the brake/accelerator pedals must be used to position the throttle plate during the compression test. The engine cranking diagnostic mode is a PCM strategy which is separate from the normal operating strategy. It allows the engine to crank in a similar fashion as a conventional vehicle with the fuel disabled. When in this mode, the PCM commands the Transmission Control Module (TCM) to spin the generator, which cranks the engine with the speed between 900 and 1,200 rpm. The engine will crank as long as the traction battery state of charge stays greater than 35%. 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level. Operate the vehicle until the engine is at normal operating temperature. 2. Using the Vehicle Communication Module (VCM), access the Battery Control Module (BCM) and monitor the traction battery state of charge PID. If the monitored PID displays the state of charge below 45%, start and idle the engine with full A/C ON. When the traction battery state of charge exceeds 45%, the engine cranking diagnostic mode can be activated. 3. Turn the ignition switch to the OFF position, then remove all the spark plugs. 4. Install a compression gauge in the No. 1 cylinder. 5. Activate the cranking diagnostic mode as follows: - Apply the parking brake. - Place the gear selector in the PARK position. - Verify the key is in the OFF position. - NOTE: Do not crank the engine. Turn the key to the ON position with the engine OFF. - Within 5 seconds of the key in the ON position, fully apply the accelerator pedal and hold for 10 seconds. - Within 5 seconds release the accelerator pedal, shift the gear selector to the NEUTRAL position and fully apply the accelerator pedal. - Hold the accelerator pedal fully applied for 10 seconds. - Release the accelerator pedal and shift the gear selector to the PARK position. If the sequence is correctly executed, the instrument cluster hazard indicator (red triangle) flashes once per second when the gear selector is shifted to the PARK position. The PCM exits the engine cranking diagnostic mode when the traction battery state of charge drops below 35%, the gear selector is shifted to any gear other than PARK or when the ignition key is turned to the OFF or ACC position. 6. NOTE: If the ignition key stays in the START position for 15 seconds or longer, the PCM may set DTC P2535. NOTE: If the brake pedal is not depressed and held prior to depressing the accelerator pedal, the throttle plate will fail to open. Crank the engine as follows: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2409 - Depress and hold the brake pedal. - Fully depress and hold the accelerator pedal. - Turn the key to the START position and crank the engine a minimum of 5 compression strokes and record the highest reading. Return the key to the ON position. - Release the accelerator pedal. - Release the brake pedal. 7. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 8. Position the key to the OFF position to deactivate the cranking diagnostic mode. 9. Clear all DTCs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications NOTE: The nominal clearance is: intake:............................................................................................. .........................................................................................................0.25 mm (0.0095 in). exhaust:..... .............................................................................................................................................................. .................................0.30 mm (0.0115 in). The acceptable clearances after being fully installed are: intake:........................................................ .............................................................................................................................0.22-0.28 mm (0.008-0.011 in). exhaust:..................................................................................................................... ..............................................................0.27-0.33 mm (0.010-0.013 in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2413 Valve Clearance: Adjustments Valve Clearance Check 1. Remove the valve cover. For additional information, refer to Valve Cover See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Valve Cover. 2. Remove the 5 bolts, the pin-type retainer (not shown) and the RH splash shield. - To install, tighten to 9 Nm (80 lb-in). 3. NOTE: Turn the engine clockwise only, and only use the crankshaft bolt. NOTE: Before removing the camshafts, measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure the clearance of each valve and record its location. 4. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: The nominal clearance is: intake: 0.25 mm (0.0095 in). - exhaust: 0.30 mm (0.0115 in). The acceptable clearances after being fully installed are: - intake: 0.22-0.28 mm (0.008-0.011 in). - exhaust: 0.27-0.33 mm (0.010-0.013 in). Select tappets using this formula: tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. Select the closest tappet size to the ideal tappet thickness available and mark the installation location. 5. If any tappets do not measure within specifications, install new tappets in these locations. For additional information, refer to Valve Train Components - Exploded View See: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Valve Train Components Exploded View and Valve Tappets See: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and Push Rods/Lifter / Lash Adjuster/Service and Repair/Removal and Replacement/Valve Tappets. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2418 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2419 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the powertrain control module (PCM) receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Accelerator Pedal Position (APP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2423 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2424 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. 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 volume of air 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. The MAF sensor is located between the air cleaner and the throttle body inside the air cleaner assembly. Mass Air Flow (MAF) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2425 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 screws and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2429 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2430 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The IAT sensor is integrated into the mass air flow (MAF) sensor. It is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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. A thermistor type sensor is considered a passive sensor. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in the 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 sensor provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, and ignition timing. Integrated Intake Air Temperature (IAT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 2434 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 2435 Brake Signal: Description and Operation Brake Pedal Position (BPP) Switch The BPP switch is a normally open switch that, when closed, sends a signal to the PCM when the brake pedal is applied. The PCM strategy uses this signal input to aid the PCM in determining the correct function and operation of the vehicle speed control, the electronic throttle control (ETC), and the transaxle and regenerative braking systems. The BPP switch is hard wired to the PCM and supplies positive battery voltage (+12 volts) when the brake pedal is applied. When the brake pedal is released, the BPP switch opens and no battery voltage input is sent to the PCM.The PID name for this switch is BOO1 Brake Pedal Switch (BPS) The BPS used for vehicle speed control deactivation is a normally closed switch, which supplies positive battery voltage (+12 volts) to the PCM when the brake pedal is released. When the brake pedal is applied, the normally closed switch opens and power is removed from the BPS circuit to the PCM. The normally closed BPS, along with the normally open BPP switch, is used by the PCM strategy for a brake pedal rationality test. The PCM strategy looks for each switch to change states when the brake pedal is applied and released. If a failure occurs in one or both of the brake pedal inputs a diagnostic trouble code is set and the PCM misfire on board diagnostic (OBD) monitor is disabled.The PID name for this switch is BOO2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2439 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2440 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The CMP sensor is a Hall-effect sensor that detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. The PCM also uses the CMP signal to select the correct ignition coil to fire. Typical Hall-effect CMP Sensor Camshaft Position (CMP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2441 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 3. NOTE: Lubricate the CMP sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2445 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2446 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates the 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. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between pulse wheel teeth. Typical Crankshaft Position (CKP) Sensor Crankshaft Position (CKP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2447 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts, the pin-type retainer (not shown) and the RH splash shield. 3. Turn the crankshaft clockwise until the hole in the crankshaft pulley is in the 3 o'clock position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2448 4. Remove the engine plug bolt. 5. NOTE: When the crankshaft contacts the Crankshaft TDC Timing Peg, the No. 1 cylinder will be at Top Dead Center (TDC). Install the Crankshaft TDC Timing Peg and turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg. 6. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 7. Remove the bolts and the CKP sensor. Installation 1. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6 mm x 18 mm bolt in the crankshaft pulley and thread it into the front cover. 2. Install the CKP sensor and the 2 bolts. - Do not tighten the bolts at this time. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2449 3. Adjust the CKP sensor with the Crankshaft Sensor Aligner. - Tighten the 2 CKP bolts to 7 Nm (62 lb-in). 4. Connect the CKP sensor electrical connector. 5. Remove the 6 mm x 18 mm bolt from the crankshaft pulley. 6. Install the engine plug bolt. - Tighten to 20 Nm (177 lb-in). 7. Install the RH splash shield, 5 bolts and the pin-type retainer (not shown). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2453 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 2457 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 2458 Electronic Throttle Actuator: Description and Operation Throttle Actuator Control (TAC) Motor The TAC motor is a DC motor controlled by the PCM (requires two wires). The motor housing is integrated into the main housing. An internal spring is used to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore. This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. For additional information, REFER to Torque Based Electronic Throttle Control (ETC) See: Electronic Throttle Control Module/Description and Operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation Torque-Based Electronic Throttle Control (ETC) Overview The torque-based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. Electronic Throttle Body (ETB) The ETB has the following characteristics: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires two wires). - An internal spring is used to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore. This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. - The required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. - There is one reference voltage and one signal return circuit between the PCM and the ETB. The reference voltage and the signal return circuits are shared with the reference voltage and signal return circuits used by the accelerator pedal position (APP) sensor. There are also two throttle position (TP) signal circuits for redundancy. The redundant TP signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor For additional information on the APP sensor, refer to Engine Control Components See: Description and Operation/Engine Control Components. Electronic Throttle Control (ETC) System Strategy The torque-based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize the fuel control while delivering the requested torque. The ETC monitor system is distributed across two processors within the PCM: the main powertrain control processor unit (CPU) and a separate monitoring processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, appropriate corrective action is taken. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2462 ECT System Failure Mode Effects Management (FMEM) Electronic Throttle Monitor Operation a Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Accelerator Pedal Position (APP) and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check a Correlation and range/performance - sensor disagreement between processors internal to the PCM. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions See: Testing and Inspection/Diagnostic Trouble Code Descriptions for additional DTC information. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2463 Throttle Position (TP) Sensor Check a Correlation and range/performance - sensor disagreement between processors internal to the PCM, TP inconsistent with requested throttle plate position. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions See: Testing and Inspection/Diagnostic Trouble Code Descriptions for additional DTC information. Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check a Note: For all DTCs, in addition to the MIL, the powertrain malfunction indicator (wrench) is on for the concern that caused the FMEM action. Monitor execution is continuous. Monitor false detection duration is less than 5 seconds to register a concern. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Engine Control Module: Customer Interest Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2472 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0442/P0456/P1450 TSB 10-1-3 02/01/10 HYBRID ONLY - DTCS P0442, P0456 OR P1450 - BUILT ON OR BEFORE 4/6/2009 FORD: 2010 Fusion 2009 Escape MERCURY: 2010 Milan 2009 Mariner This article supersedes TSB 09-9-9 to add a production fix date. ISSUE Some 2009 Escape Hybrid, Mariner Hybrid, 2010 Fusion Hybrid and Milan Hybrid vehicles built on or before 4/6/2009 may exhibit a malfunction indicator light (MIL) accompanied by diagnostic trouble code (DTC) P0442, P0456 or P1450. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Follow the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostic procedures for any DTC code that may be present to ensure the Evaporative Emissions (EVAP) system is functioning properly. 2. When performing EVAP diagnostics on Escape Hybrid and Mariner Hybrid vehicles, the ambient temperature must be greater than 32 °F (0 °C) and the heating ventilation air conditioning (HVAC) system should be set to Defrost. This will provide continuous gasoline engine operation. 3. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 60.11 and higher or 61.01 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 100103A 2010 Fusion Hybrid/Milan 0.3 Hr. Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) 100103A 2009 Escape 0.3 Hr. Hybrid/Mariner Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 2477 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Engine Control Module: All Technical Service Bulletins Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2483 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0442/P0456/P1450 TSB 10-1-3 02/01/10 HYBRID ONLY - DTCS P0442, P0456 OR P1450 - BUILT ON OR BEFORE 4/6/2009 FORD: 2010 Fusion 2009 Escape MERCURY: 2010 Milan 2009 Mariner This article supersedes TSB 09-9-9 to add a production fix date. ISSUE Some 2009 Escape Hybrid, Mariner Hybrid, 2010 Fusion Hybrid and Milan Hybrid vehicles built on or before 4/6/2009 may exhibit a malfunction indicator light (MIL) accompanied by diagnostic trouble code (DTC) P0442, P0456 or P1450. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Follow the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostic procedures for any DTC code that may be present to ensure the Evaporative Emissions (EVAP) system is functioning properly. 2. When performing EVAP diagnostics on Escape Hybrid and Mariner Hybrid vehicles, the ambient temperature must be greater than 32 °F (0 °C) and the heating ventilation air conditioning (HVAC) system should be set to Defrost. This will provide continuous gasoline engine operation. 3. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 60.11 and higher or 61.01 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 100103A 2010 Fusion Hybrid/Milan 0.3 Hr. Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) 100103A 2009 Escape 0.3 Hr. Hybrid/Mariner Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 2488 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2489 Engine Control Module: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2490 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2491 Engine Control Module: Diagrams Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2492 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2493 Part 3 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2494 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2495 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2496 Part 3 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2497 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2498 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory (EEPROM) WARNING: THIS VEHICLE IS EQUIPPED WITH HIGH VOLTAGE CABLES, COMPONENTS, AND WIRING. THE HIGH VOLTAGE WARNING LABELS CONTAINING THE HIGH VOLTAGE SYMBOL ARE LOCATED ON EACH HIGH VOLTAGE COMPONENT. HIGH VOLTAGE CABLES AND WIRING ARE ORANGE IN COLOR. CERTIFIED RUBBER INSULATING GLOVES AND A FACE SHIELD MUST BE WORN WHEN WORKING WITH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING. THE IGNITION KEY MUST BE CYCLED TO THE OFF POSITION FOR A MINIMUM OF 5 MINUTES, AND THE HIGH VOLTAGE TRACTION BATTERY SERVICE DISCONNECT PLUG PLACED IN THE SERVICING/SHIPPING POSITION BEFORE DISCONNECTING THE HIGH VOLTAGE CABLES. DO NOT DISCONNECT, DISABLE, OR TOUCH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING DURING THE MODULE REPROGRAMMING PROCEDURE BECAUSE HIGH VOLTAGE IS PRESENT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH. Description Flash electrically erasable programmable read only memory (EEPROM) is contained in an integrated circuit internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block must be programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate diagnostic trouble code (DTC) P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. Failure to carry out this procedure correctly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, and the presence of speed control. Only items applicable to vehicle hardware and supported by the VID block are displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. On selected vehicles equipped with permanent DTC reporting capabilities, neutral profile correction should be learned after a PCM replacement in order to activate the misfire monitor. This can be accomplished using the Misfire Monitor Neutral Profile Learn function on the scan tool. Reprogramming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the manufacturer's user manual for details. Programming the VID Block for a Replacement PCM The VID block on a replacement PCM is blank and requires programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it is replaced. Manual data entry must be carried out if the old module is damaged and is incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the Module/Parameter programming, referring to the manufacturer's user manual. Make certain that all parameters are included. Failure to correctly program tire size in revolutions per mile, (rev/mile = 63,360 divided by the tire circumference in inches) or axle ratio, may result in codes P1635 and P1639. You may be instructed to contact the As Built data center for the information needed to manually update the VID block with the scan tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury technicians, contact the National Hotline or Professional Technician Society (PTS) website for As Built data. Non-Ford technicians, use the Motorcraft website at Motorcraft.com. From the Motorcraft homepage, use the search function to find the Module Programming or As Built Data. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the scan tool. PCM Reprogramming Note: After the PCM is successfully reprogrammed, clear any TCM DTCs that may have been stored during reprogramming. At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2501 Engine Control Module: Removal and Replacement Powertrain Control Module (PCM) Removal 1. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation (PMI) procedure. See: Information Bus/Testing and Inspection/Programming and Relearning 2. Detach the wiring harness retainer from the cowl stud bolt. 3. Disconnect the 3 PCM electrical connectors. 4. Remove the 2 bolts and the PCM. 5. Remove and inspect the PCM cowl seal. Install new if damaged. Installation 1. Install the PCM cowl seal. 2. Install the PCM and the 2 bolts. - Tighten to 8 Nm (71 lb-in). 3. Connect the 3 PCM electrical connectors. 4. Attach the wiring harness retainer to the cowl stud bolt. 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation (PMI) procedure. See: Information Bus/Testing and Inspection/Programming and Relearning Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2505 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2506 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which the resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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 varying the resistance of the passive sensor causes a variation in total current flow. The CHT sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor provides 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 then initiates 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 See: Description and Operation/Powertrain Control Software Fail-Safe Cooling Strategy. Cylinder Head Temperature (CHT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2507 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. Detach the Cylinder Head Temperature (CHT) sensor cover and position aside. 2. Disconnect the CHT sensor electrical connector. 3. Remove the CHT sensor. - To install, tighten to 12 Nm (106 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Level Sensor: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Fuel Tank Filler Pipe Assembly Fuel Tank and Fuel Pump (FP) module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2512 Fuel Tank Supports Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2513 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2514 Fuel Level Sensor: Service and Repair Fuel Pump Module Fuel Pump Module Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the Fuel Pump (FP) module access cover. 4. NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material. Disconnect the FP module electrical connector. 5. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage. Disconnect the fuel tube-to-FP module quick connect coupling. 6. Disconnect the fuel tank filler pipe recirculation tube-to-FP module quick connect coupling. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2515 7. NOTE: For initial fuel draining, it is required to remove the fuel through the fuel tank filler pipe recirculation tube port on the FP module. Connect the Fuel Storage Tanker to the fuel tank filler pipe recirculation tube port on the FP module and remove approximately one-fourth of the fuel (from a completely full tank), lowering the fuel level below the FP module mounting flange. 8. NOTICE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP module when removing the lock ring. NOTE: When installing the FP module, install a new O-ring seal. Install the Fuel Tank Sender Unit Wrench and remove the FP module lock ring. 9. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm. NOTE: Some residual fuel may remain in the FP module. Carefully drain into a suitable container. Completely remove the FP module from the fuel tank. 10. NOTE: Inspect the surfaces of the FP module flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded. NOTE: To install, apply clean engine oil to the O-ring seal. Remove and discard the FP module O-ring seal. 11. NOTE: Make sure to install a new FP module O-ring seal and lock ring. To install, reverse the removal procedure. Make sure the alignment arrows on the FP module and the fuel tank meet before tightening the FP module lock ring. - Tighten the FP lock ring until it meets the stop tabs on the fuel tank. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2516 Fuel Level Sensor: Service and Repair Fuel Level Sender Fuel Level Sender Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the Fuel Pump (FP) module. For additional information, refer to Fuel Pump Module See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Pump Module. 2. Disconnect the electrical connector, release the locking tabs and remove the fuel level sender from the FP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2517 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 2521 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor The FTP sensor is used to measure the fuel tank pressure. In-line Fuel Tank Pressure (FTP) Sensor Fuel Tank Pressure (FTP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2526 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2527 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2528 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2529 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2530 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2531 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2532 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2533 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2534 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2535 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2536 Information Bus: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2537 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2538 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2539 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2540 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2541 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2542 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2543 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2544 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2545 Information Bus: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 14-1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2546 14-2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2547 14-3 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2548 Information Bus: Description and Operation Communications Network - Hybrid Vehicle communication utilizes both ISO 9141 and Controller Area Network (CAN) communications. ISO 9141 is used for diagnostic use only while CAN allows many modules to communicate with each other on a common network. CAN in-vehicle networking is a method for transferring data among distributed electronic modules via a serial data bus. Without serial networking, intermodule communication requires dedicated, point to point wiring resulting in bulky, expensive, complex, and difficult to install wiring harnesses. Applying a serial data network reduces the number of wires, combining the signals on a single network. Information is sent to the individual control modules that control each function. The vehicle has 3 module communication networks: - ISO 9141 - Medium Speed Controller Area Network (MS-CAN) - High Speed Controller Area Network (HS-CAN) All 3 networks are connected to the Data Link Connector (DLC). This makes diagnosis and testing of these systems easier by allowing one scan tool to be able to diagnose and control any module on the 3 networks from one connector. The DLC can be found under the instrument panel between the steering column and the Audio Control Module (ACM). Network Topology Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2549 ISO 9141 Network Operation The ISO 9141 communications network is a single wire network, used for diagnostic purposes only. The ISO 9141 communications network is used for the following module: - Parking Aid Module (PAM) Medium Speed Controller Area Network (MS-CAN) Operation The MS-CAN communicates using bussed messages. The MS-CAN has an unshielded twisted pair cable, data bus (+) and data bus (-) circuits. In addition to scan tool communication, this network allows sharing of information between all modules on the network. The MS-CAN is a medium speed communication network used for the following modules: - Accessory Protocol Interface Module (APIM) (if equipped) - Audio Control Module (ACM) - HVAC module - Front Controls Interface Module (FCIM) - Front Display Interface Module (FDIM) - Instrument Cluster (IC) - Satellite Digital Audio Receiver System (SDARS) module - Smart Junction Box (SJB) High Speed Controller Area Network (HS-CAN) Operation The HS-CAN communicates using bussed messages. The HS-CAN uses an unshielded twisted pair cable, data bus (+) and data bus (-) circuits. In addition to scan tool communication, this network allows sharing of information between all modules on the network. The HS-CAN is a high speed communication network used for the following modules: - 4X4 control module - ABS module - APIM (if equipped) - Battery Control Module (BCM) - Instrument Cluster (IC) - Occupant Classification System Module (OCSM) - PCM Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2550 - Power Steering Control Module (PSCM) - Restraints Control Module (RCM) - Transmission Control Module (TCM) Network Termination The CAN uses a network termination circuit to improve communication reliability. The network termination of the CAN bus takes place inside the termination modules by termination resistors. Termination modules are located at either end of the bus network. As network messages are broadcast, in the form of voltage signals, the network voltage signals are stabilized by the termination resistors. Each termination module has a 120 ohm resistor across the positive and negative bus connection in the termination module. With 2 termination modules on each network, and the 120 ohm resistors located in a parallel circuit configuration, the total network impedance, or total resistance, is 60 ohms. Network termination improves bus message reliability by: - Stabilizing bus voltage - Eliminating electrical interference Gateway Module The Instrument Cluster (IC) is the gateway module, translating HS-CAN to MS-CAN and vice versa. This information allows a message to be distributed throughout both networks. The IC is the only module on this vehicle that has this ability. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Special Tools Used With Diagnostics Communications Network Principles Of Operation Communications Network Principles of Operation Vehicle communication utilizes both International Standards Organization (ISO) 9141 and Controller Area Network (CAN) communications. ISO 9141 is used for diagnostic use only, and CAN is a method for transferring data among distributed electronic modules via a serial data bus. The vehicle is equipped with 3 module communication networks: - ISO 9141 - Medium Speed Controller Area Network (MS-CAN) - High Speed Controller Area Network (HS-CAN) ISO 9141 Communications Network The ISO 9141 communications network is a single wire network. The ISO communications network does not permit intermodule communication and is only used for the Parking Aid Module (PAM). When the scan tool communicates with the parking aid module, the scan tool must request all information, the module cannot initiate communications. The ISO network operates at a maximum data transfer speed of 10 Kbps for bus messages and is designed for scan tool to module diagnostic use only. The following fault chart describes the specific ISO 9141 network failures and their resulting symptom: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2553 ISO 9141 Network Communication Fault Chart Medium Speed Controller Area Network (MS-CAN) The MS-CAN uses an unshielded twisted pair cable of data (+) and data (-) circuits. The data (+) and the data (-) circuits are each regulated to approximately 2.5 volts during neutral or rested network traffic. As bus messages are sent on the data (+) circuit, voltage is increased by approximately 1.0 volt. Inversely, the data (-) circuit is reduced by approximately 1.0 volt when a bus message is sent. Multiple bus messages can be sent over the CAN circuits allowing multiple modules to communicate with each other. The MS-CAN is used for the Instrument Cluster (IC), the Front Controls Interface Module (FCIM), the Front Display Interface Module (FDIM), HVAC module, the Audio Control Module (ACM), the APIM, the Satellite Digital Audio Receiver System (SDARS) module and the Smart Junction Box (SJB) communications, and is designed for general information transfer. The MS-CAN will not communicate while certain faults are present, but will operate with diminished performance with other faults present. The MS-CAN bus may remain operational when 1 of the 2 termination resistors are not present. The MS-CAN operates at a maximum data transfer speed of 125 Kbps for bus messages and is designed for general information transfer. The network will remain operational, but at a degraded level when certain circuit faults are present. The following fault chart describes the specific MS-CAN failures and their resulting symptom: MS-CAN Communication Fault Chart High Speed Controller Area Network (HS-CAN) The HS-CAN uses an unshielded twisted pair cable of data (+) and data (-) circuits. The data (+) and the data (-) circuits are each regulated to approximately 2.5 volts during neutral or rested network traffic. As bus messages are sent on the data (+) circuit, voltage is increased by approximately 1.0 volt. Inversely, the data (-) circuit is reduced by approximately 1.0 volt when a bus message is sent. Multiple bus messages can be sent over the CAN circuits allowing multiple modules to communicate with each other. The HS-CAN is a high speed communication network used for the Instrument Cluster (IC), the PCM, the ABS module, the APIM, the Occupant Classification System Module (OCSM), Restraints Control Module (RCM), the Battery Control Module (BCM), the Transmission Control Module (TCM), the Power Steering Control Module (PSCM) and the 4X4 control module communications, and designed for real time information transfer and control. The HS-CAN will not communicate while certain faults are present, but will operate with diminished performance with other faults present. The HS-CAN bus may remain operational when 1 of the 2 termination resistors are not present. The HS-CAN operates at a maximum data transfer speed of 500 Kbps and is designed for real time information transfer and control. The network will remain operational, but at a degraded level when certain circuit faults are present. The following fault chart describes the specific HS-CAN failures and their resulting symptom: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2554 HS-CAN Communication Fault Chart The following chart describes the specific CAN messages broadcast by each module, and the module(s) that receive the message: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2555 CAN Module Communication Message Chart - Escape and Mariner (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2556 CAN Module Communication Message Chart - Escape and Mariner (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2557 CAN Module Communication Message Chart - Escape and Mariner (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2558 CAN Module Communication Message Chart - Escape and Mariner (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2559 CAN Module Communication Message Chart - Hybrid (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2560 CAN Module Communication Message Chart - Hybrid (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2561 CAN Module Communication Message Chart - Hybrid (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2562 CAN Module Communication Message Chart - Hybrid (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2563 CAN Module Communication Message Chart - Hybrid (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2564 CAN Module Communication Message Chart - Hybrid (Part 6) Inspection And Verification Communications Network Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. - If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2565 Visual Inspection Chart 3. Connect the scan tool to the Data Link Connector (DLC). - NOTE: Make sure to use the latest scan tool software release. NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the Integrated Diagnostic System (IDS) does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Go To Pinpoint Test V, to diagnose No Power To The Scan Tool. See: Pinpoint Tests/Pinpoint Test V: No Power To The Scan Tool 4. Establish a scan tool session. - NOTE: The scan tool will first attempt to communicate with the PCM, after establishing communication with the PCM, the scan tool will then attempt to communicate with all other modules on the vehicle. If an IDS session cannot be established wit the vehicle, (IDS may state "No communication can be established with the PCM"): Choose "NO" when the scan tool prompts whether or not to retry communication. - Enter either a PCM part number, tear tag or calibration number to identify the vehicle and start a session. 5. Carry out the network test. - If the network test passes, retrieve and record the continuous memory DTCs and proceed to Step 6. - If the network test fails, GO to Symptom Chart to diagnose the failed communication network. See: Symptom Related Diagnostic Procedures - If a module fails to communication during the network test, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures 6. Retrieve and review the DTCs. - If the DTCs retrieved are related to the concern, go to DTC Charts. Follow the non-network DTC diagnostics (B-codes, C-codes, P-codes) prior to the network DTC diagnostics (U-codes). For all other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart in Body Control Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2566 Systems. See: Diagnostic Trouble Code Descriptions/Communications Network See: Body and Frame/Body Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart - If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Special Tools Used With Diagnostics Module Configuration Principles Of Operation Module Configuration Principles of Operation Configurable modules accommodate a variety of vehicle options, eliminating the need for many unique modules for one vehicle line. These modules must be configured when replaced as part of a repair procedure. Configurable modules should not be exchanged between vehicles since the settings are unique to each vehicle. Failure to configure a new module may result in incorrect operation and/or DTCs setting. The following are the 3 different methods of configuration: - Programmable Module Installation (PMI) - Module reprogramming ("flashing") - Programmable parameters Some modules do not support all 3 methods. Definition of Terms The following are definitions of configuration terms: Programmable Module Installation (PMI) PMI is a scan tool process which configures settings in a new module. Data used for the PMI process is automatically downloaded from the original module and stored when a scan tool session is started. If this data cannot be retrieved from the module being replaced, the scan tool may prompt for As-Built data entry or display a list of parameter values that need to be manually selected. Some modules are reprogrammed during PMI when a strategy/calibration update is available. To carry out PMI, refer to Programmable Module Installation (PMI) See: Service and Repair. NOTE: It is important that the scan tool identifies the vehicle and obtains configuration data prior to removing any modules. The new module must be able to communicate with the scan tool in order to carry out PMI. See: Programming and Relearning Module Reprogramming Module reprogramming (also referred to as "flashing") is a scan tool process which updates the strategy/calibration in a module. Reprogramming a module with the same level of software will not improve module operation or repair a hardware failure. Module reprogramming is automatically carried out during PMI when a later strategy/calibration is available. NOTE: Module reprogramming should be limited to circumstances where a published TSB procedure recommends doing so. NOTE: A module cannot communicate with other modules on the communication network while being reprogrammed. Clear any network communication DTCs which may have been set in other modules during the reprogramming process. Accessory Protocol Interface Module (APIM) Programming Accessory Protocol Interface Module (APIM) programming is a process that updates the APIM Consumer Interface Processor (CIP) and Vehicle Interface Processor (VIP) software. The VIP programming updates the calibration files in the portion of the APIM which interfaces with the Controller Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2567 Area Network (CAN). The CIP programming updates calibration files in the portion of the APIM that interfaces with mobile phones and other customer devices. APIM programming uses the Vehicle Communication Module (VCM) to read and program the VIP software through the Data Link Connector (DLC). A web-based On-Line Automotive Service Information System (OASIS) application is used to read and program the CIP software via a Universal Serial Bus (USB) cable between the scan tool and vehicle USB port. Both the VCM and OASIS application must be running on the scan tool during APIM programming. To carry out APIM programming, refer to Accessory Protocol Interface Module (APIM) Programming See: Programming and Relearning/Accessory Protocol Interface Module (APIM) Programming. Programmable Parameters Programmable parameters are customer preference items that may be modified by the dealer via scan tool or in some cases modified by the customer following a procedure listed in the vehicle Owner's Literature. While many configuration options may exist for a module, only a few of these options are programmable parameters. Adaptive Learning and Calibration Some modules require a separate learning procedure be carried out if replaced as part of a repair procedure. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. Transmission Identification Block Some PCMs contain a memory area called a transmission identification block. The PCM transmission identification block stores solenoid body flow data. If the solenoid body information is not correct, transaxle damage or driveability concerns can occur. Vehicle Identification (VID) Block Some PCMs contain a memory area called a Vehicle Identification (VID) block. The PCM VID block commonly stores powertrain configuration items such as Vehicle Identification Number (VIN), tire size, axle ratio, and whether or not the vehicle is equipped with speed control. Module Address A unique module address is assigned to each module on the network for identification. As-Built Data As-Built data is a VIN-specific module configuration record. During vehicle build, the configuration from all modules is downloaded and stored in the As-Built database. As-Built data will not reflect customer preference items that have been changed from the default state. These items will need to be changed using programmable parameters after the module is configured. NOTE: It is not necessary to obtain As-Built data unless directed to do so by the scan tool. This data may be accessed from the technician service publication website. The following chart lists As-Built data addresses and describes specific module configuration information: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2568 Module Configuration and Parameter Chart - Escape and Mariner (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2569 Module Configuration and Parameter Chart - Escape and Mariner (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2570 Module Configuration and Parameter Chart - Hybrid (Part 1) Module Configuration and Parameter Chart - Hybrid (Part 2) Inspection And Verification Module Configuration Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2571 Inspection and Verification This provides step-by-step module configuration procedures. Carry out the Programmable Module Installation (PMI) procedures when another diagnostic/repair information directs to carry out configuration or when DTCs from the below list are present: See: Programming and Relearning Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2572 Information Bus: Diagnostic Trouble Code Descriptions Communications Network Communications Network DTC Charts NOTE: Network DTCs (U-codes) are often a result of intermittent concerns such as faulty wiring or low battery voltage occurrences. Additionally, vehicle service procedures such as module reprogramming will often set network DTCs. Replacing a module to resolve a network DTC is unlikely to resolve the concern. To prevent repeat network DTC concerns, inspect all network wiring, especially connectors. Test the vehicle battery, refer to Battery. NOTE: Some modules on this vehicle utilize a 5-character DTC followed by a 2-character failure-type code. The failure-type code provides information about specific fault conditions such as opens, or shorts to ground. Continuous memory DTCs have an additional 2-character DTC status code suffix to assist in determining DTC history. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2573 U0001-U0114 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2574 U0114:00-U0151:87 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2575 U0151:88-U0162:00 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2576 U0163-U0255 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2577 U0255:00-U0423:00 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2578 U261A-U3000:88 Module Configuration Module Configuration Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2579 B2477-B2900 / P0602-P1639 / U201A:51-U0300:51 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2580 U2050-U3002:62 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2581 Information Bus: Symptom Related Diagnostic Procedures Communications Network Symptom Chart Symptom Chart (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2582 Symptom Chart (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2583 Information Bus: Pinpoint Tests Pinpoint Test A: The PCM Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test A: The PCM Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 23 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Electronic Engine Controls - 2.5L for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 24 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Electronic Engine Controls - 3.0L for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The PCM communicates with the scan tool through the High Speed Controller Area Network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the PCM. Voltage for the PCM is provided by circuit CBB28 (GY/VT) or SBB05 (GY/RD). Circuit GD122 (BK) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - ABS module - Accessory Protocol Interface Module (APIM) - 4X4 control module (if equipped) - IC - PCM - RCM - PSCM - OCSM - TCM (Hybrid only) - BCM (Hybrid only) PINPOINT TEST A: THE PCM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- A1 VERIFY WHETHER OTHER HS-CAN MODULES PASS THE NETWORK TEST - Ignition ON. - Enter the following diagnostic mode on the scan tool: Network Test. - In the left hand pane of the IDS network test display screen, verify whether any HS-CAN modules passed the network test. - Is the text "pass" or a DTC listed next to any of the following modules (if equipped): 4x4 control module, ABS module, Accessory Protocol Interface Module (APIM), Battery Control Module (BCM), Instrument Cluster (IC), Occupant Classification System Module (OCSM), Power Steering Control Module (PSCM), Restraints Control Module (RCM), Transmission Control Module (TCM) or PCM? Yes If "pass" or a DTC was listed next to the PCM, a network fault is not currently present. Go To Pinpoint Test R to diagnose an intermittent HS-CAN fault condition. See: Pinpoint Test R: Intermittent No High Speed Controller Area Network (HS-CAN) Communication, Communication Can Be Intermittently If "pass" or a DTC was listed next to one or more modules other than the PCM, GO to A2. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2584 No No modules are currently communicating on the HS-CAN. Go To Pinpoint Test s to diagnose no HS-CAN communication. See: Pinpoint Test S: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------- A2 VERIFY COMPUTERS AND CONTROL SYSTEMS INFORMATION PINPOINT TEST QA HAS BEEN CARRIED OUT - Verify that pinpoint test QA has been carried out. - Has pinpoint test QA been carried out? Yes GO to A3. No REFER to Computers and Control Systems Information, Pinpoint Tests, pinpoint test QA to diagnose no communication with the PCM. ------------------------------------------------- A3 CHECK THE HS-CAN TERMINATION RESISTANCE - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance between 54 and 66 ohms? Yes CONNECT the negative battery cable. GO to A5. No GO to A4. ------------------------------------------------- A4 CHECK THE CAN CIRCUITS BETWEEN THE PCM AND THE DLC FOR AN OPEN - Measure the resistance between the PCM C175b-59, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the PCM C175b-58, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2585 - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to A5. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- A5 CHECK FOR CORRECT PCM OPERATION - Disconnect all the PCM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the PCM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new PCM. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test B: The ABS Module Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test B: The ABS Module Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 42 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Vehicle Dynamic Systems for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation - Escape and Mariner The ABS module communicates with the scan tool through the High Speed Controller Area Network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the ABS module. Voltage for the ABS module is provided by circuits CBP34 (VT/BN), SBB09 (RD) and SBB18 (YE/RD). Ground is provided by circuit GD120 (BK/GN). Hybrid The ABS module communicates with the scan tool through the High Speed Controller Area Network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the ABS module. Voltage for the ABS module is provided by circuits CBP34 (VT/BN), CBK03 (GY), SBB09 (RD) and SBB18 (YE/RD). Ground is provided by circuit GD113 (BK/YE) and GD120 (BK/GN) . Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2586 This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - ABS module PINPOINT TEST B: THE ABS MODULE DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- B1 CHECK THE ABS MODULE VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: ABS Module C155. - Ignition ON. - Measure voltage between the ABS module, harness side and ground as follows: Escape And Mariner - Are the voltages greater than 10 volts? Yes GO to B2. No Escape and Mariner, VERIFY the Battery Junction Box (BJB) fuse 18 (20A) and fuse 9 (50A) and the Smart Junction Box (SJB) fuse 34 (5A) are OK. If OK, REPAIR the circuit in question. If not OK, refer to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. Hybrid, VERIFY the Battery Junction Box (BJB) fuses 27 (20A), 9 (50A) and 18 (20A) and the Smart Junction Box (SJB) fuse 34 (5A) are OK. If OK, REPAIR the circuit in question. If not OK, refer to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- B2 CHECK THE ABS MODULE GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the ABS module, harness side and ground as follows: Escape And Mariner Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2587 Hybrid - Are the resistances less than 5 ohms? Yes GO to B3. No REPAIR the circuit. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- B3 CHECK THE HS-CAN CIRCUITS BETWEEN THE ABS MODULE AND THE DLC FOR AN OPEN - Measure the resistance between the ABS module C155-12, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the ABS module C155-13, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to B4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- B4 CHECK FOR CORRECT ABS MODULE OPERATION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2588 - Disconnect the ABS module connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the ABS module connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new ABS module. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test C: The 4X4 Control Module Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test C: The 4X4 Control Module Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 34 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Four Wheel Drive Systems for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The 4X4 control module communicates with the scan tool through the High Speed Controller Area Network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the 4X4 control module. Voltage for the 4X4 control module is provided by circuits CBP35 (YE/GY) and SBP11 (BU/RD). Ground is provided by circuit GD182 (BK/GY). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - 4X4 control module PINPOINT TEST C: THE 4X4 CONTROL MODULE DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- C1 CHECK THE 4X4 CONTROL MODULE VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: 4X4 Control Module C3184. - Ignition ON. - Measure the voltage between the 4X4 control module C3184-4, circuit CBP35 (YE/GY), harness side and ground; and between the 4X4 control module C3184-5, circuit SBP11 (BU/RD), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2589 - Are the voltages greater than 10 volts? Yes GO to C2. No VERIFY the Smart Junction Box (SJB) fuse 11 (10A) and 35 (10A) are OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- C2 CHECK THE 4X4 CONTROL MODULE GROUND CIRCUIT - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the 4X4 control module C3184-15, circuit GD182 (BK/GY), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to C3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- C3 CHECK THE HS-CAN CIRCUITS BETWEEN THE 4X4 CONTROL MODULE AND THE DLC FOR AN OPEN - Measure the resistance between the 4X4 control module C3184-3, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the 4X4 control module C3184-11, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2590 - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to C4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- C4 CHECK FOR CORRECT 4X4 CONTROL MODULE OPERATION - Disconnect the 4X4 control module connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the 4X4 control module connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new 4X4 control module. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test D: The Instrument Cluster (IC) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test D: The Instrument Cluster (IC) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 60 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Instrument Cluster for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Instrument Cluster (IC) communicates with the scan tool through the High Speed Controller Area Network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the HS-CAN connection to the IC and circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the Medium Speed Controller Area Network (MS-CAN) connection to the IC. Voltage for the IC is provided by circuits CBP29 (WH/VT), and SBP26 (YE/RD). Circuits GD112 (BK/GN) and GD114 (BK/BU) provide ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2591 - IC PINPOINT TEST D: THE IC DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- D1 CHECK THE HS-CAN TERMINATION RESISTANCE - Ignition OFF. - Disconnect: Negative Battery Cable. - Disconnect the scan tool cable from the Data Link Connector (DLC). - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance between 54 and 66 ohms? Yes GO to D2. No CONNECT the negative battery cable. GO to D4. ------------------------------------------------- D2 CHECK THE IC GROUND CIRCUIT FOR AN OPEN - Disconnect: IC C220. - Measure the resistance between the IC C220-9, circuit GD112 (BK/GN) harness side and ground. - Is the resistance less than 5 ohms? Yes CONNECT the negative battery cable. GO to D3. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- D3 CHECK THE IC VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - Ignition ON. - Measure the voltage between the IC, harness side and ground as follows: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2592 - Are the voltages greater than 10 volts? Yes GO to D4. No VERIFY the Smart Junction Box (SJB) fuses 26 (10A), 29 (5A) or 43 (10A) are OK. If OK, REPAIR the circuit in question. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- D4 CHECK THE HS-CAN CIRCUITS BETWEEN THE IC AND THE DLC FOR AN OPEN - Ignition OFF. - Measure the resistance between the IC C220-15, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the IC C220-14, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances less than 5 ohms? Yes GO to D5. No REPAIR the circuit in question. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- D5 CHECK THE MS-CAN CIRCUITS BETWEEN THE DLC AND THE IC FOR AN OPEN - Measure the resistance between the IC C220-2, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2593 - Measure the resistance between the IC C220-1, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes GO to D6. No REPAIR the circuit in question. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- D6 CHECK FOR CORRECT IC OPERATION - Disconnect the IC connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the IC connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new IC. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test E: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test E: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 46 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Supplemental Restraint Systems for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2594 Normal Operation The Restraints Control Module (RCM) communicates with the scan tool through the High Speed Controller Area Network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the HS-CAN connection to the RCM. Voltage for the RCM is provided by circuits CBP31 (BN/OG) and the RCM is case grounded. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - RCM PINPOINT TEST E: THE RCM DOES NOT RESPOND TO THE SCAN TOOL WARNING: Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and verification before proceeding with the Pinpoint Test. See: Initial Inspection and Diagnostic Overview/Communications Network/Inspection And Verification ------------------------------------------------- E1 CHECK THE RCM CONNECTION - Ignition OFF. - Depower the SRS. Refer to Air Bag Systems. - Disconnect: RCM C2041a. - Disconnect: RCM C2041b. - Are RCM C2041a and C2041b pins OK? Yes GO to E2. No REPAIR the RCM connector pins as necessary. REPOWER the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- E2 CHECK THE RCM CASE GROUND FOR AN OPEN - Measure the resistance between the metal RCM case and a good chassis ground. Is the resistance less than 5 ohms? Yes GO to E3. No REPAIR the case ground connection. REPOWER the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- E3 CHECK THE RCM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Repower the SRS. Refer to Air Bag Systems. - Ignition ON. - Measure the voltage between the RCM C2041a-13, circuit CBP31 (BN/OG), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2595 - Is the voltage greater than 10 volts? Yes GO to E4. No VERIFY the Smart Junction Box (SJB) fuse 31 (10A) is OK. If OK, REPAIR the circuit in question. REPOWER the SRS. REFER to Air Bag Systems. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- E4 CHECK THE HS-CAN CIRCUITS BETWEEN THE RCM AND THE DLC FOR AN OPEN - Ignition OFF. - Measure the resistance between the RCM C2041b-10, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the RCM C2041b-9, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances less than 5 ohms? Yes GO to E5. No REPAIR the circuit in question. REPOWER the SRS. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- E5 CHECK FOR CORRECT RCM OPERATION - Disconnect all the RCM connectors. - Check for: corrosion - damaged pins Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2596 - pushed-out pins - Connect all the RCM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new RCM. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test F: The Occupant Classification System Module (OCSM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test F: The Occupant Classification System Module (OCSM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 46 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Supplemental Restraint Systems for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Occupant Classification System Module (OCSM) communicates with the scan tool through the High Speed Controller Area Network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the HS-CAN connection to the OCSM. Voltage for the OCSM is provided by circuit CBP46 (WH/BU) and circuit GD183 (BK/WH) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - OCSM PINPOINT TEST F: THE OCSM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- F1 CHECK THE OCSM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Disconnect: OCSM C3285. - Ignition OFF. - Ignition ON. - Measure the voltage between the OCSM C3285-1, circuit CBP46 (WH/BU), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2597 - Is the voltage greater than 10 volts? Yes GO to F2. No VERIFY the Smart Junction Box (SJB) fuse 46 (7.5A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- F2 CHECK THE OCSM GROUND CIRCUIT FOR AN OPEN - Disconnect: Negative Battery Cable. - Ignition OFF. - Measure the resistance between the OCSM C3285-14, circuit GD183 (BK/WH), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to F3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- F3 CHECK THE HS-CAN CIRCUITS BETWEEN THE OCSM AND THE DLC FOR AN OPEN - Measure the resistance between the OCSM C3285-18, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the OCSM C3285-9, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2598 - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to F4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- F4 CHECK FOR CORRECT OCSM OPERATION - Disconnect the OCSM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the OCSM connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new OCSM. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test G: The Power Steering Control Module (PSCM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test G: The Power Steering Control Module (PSCM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 43 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Power Steering Controls for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Power Steering Control Module (PSCM) communicates with the scan tool through the High Speed Controller Area Network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the HS-CAN connection to the PSCM. Voltage for the Power Steering Control Module (PSCM) is provided by circuit CBP35 (YE/GY) and circuit GD116 (BK/VT) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - PSCM Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2599 PINPOINT TEST G: THE PSCM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- G1 CHECK THE PSCM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Disconnect: PSCM C1463a (Escape and Mariner) or C2231a (Hybrid). - Ignition ON. - Measure the voltage between the PSCM C1463a-1 or C2231a-1, circuit CBP35 (YE/GY), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to G2. No VERIFY the Smart Junction Box (SJB) fuse 35 (10A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- G2 CHECK THE PSCM GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: PSCM C1463b (Escape and Mariner) or C2231b (Hybrid). - Disconnect: Negative Battery Cable. - Measure the resistance between the PSCM C1463b-2 or C2231b-2, circuit GD116 (BK/VT), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to G3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- G3 CHECK THE HS-CAN CIRCUITS BETWEEN THE PSCM AND THE DLC FOR AN OPEN - Measure the resistance between the PSCM C1463a-2 or C2231b-2, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2600 - Measure the resistance between the PSCM C1463a-3 or C2231b-3, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to G4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- G4 CHECK FOR CORRECT PSCM OPERATION - Disconnect all the PSCM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the PSCM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new steering column assembly. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test H: The Transmission Control Module (TCM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test H: The Transmission Control Module (TCM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 29 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Transmission Controls for schematic and connector information. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2601 See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Transmission Control Module (TCM) is present on Hybrid vehicles only. The TCM communicates with the scan tool through the High Speed Controller Area Network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the TCM. Voltage for the TCM is provided by circuits CBB24 (VT/GN) and SBB05 (GY/RD). Ground is provided by circuit GD121 (BK/YE). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - TCM PINPOINT TEST H: THE TCM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- H1 CHECK THE TCM VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: TCM C1458a. - Ignition ON. - Measure the voltage between the TCM, harness side and ground as follows: - Are the voltages greater than 10 volts? Yes GO to H2. No VERIFY the Battery Junction Box (BJB) fuse 5 (10A) or fuse 24 (10A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- H2 CHECK THE TCM GROUND CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the TCM harness side and ground as follows: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2602 - Are the resistances less than 5 ohms? Yes GO to H3. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- H3 CHECK THE HS-CAN CIRCUITS BETWEEN THE TCM AND THE DLC FOR AN OPEN - Measure the resistance between the TCM C1458a-1, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the TCM C1458a-7, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to H4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- H4 CHECK FOR CORRECT TCM OPERATION - Disconnect all the TCM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the TCM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2603 Yes INSTALL a new TCM. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test I: The Battery Control Module (BCM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test I: The Battery Control Module (BCM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 23 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Electronic Engine Controls - 2.3L for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Battery Control Module (BCM) is present on Hybrid vehicles only. The BCM communicates with the scan tool through the High Speed Controller Area Network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the BCM. Voltage for the BCM is provided by circuits CBB23 (BN/YE), SBB05 (GY/RD) and SBB15 (WH/RD). Ground is provided by circuits GD182 (BK/GY) and GD149 (BK/GY). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - BCM PINPOINT TEST I: THE BCM DOES NOT RESPOND TO THE SCAN TOOL NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- I1 CHECK THE POWER TO THE BCM WARNING: When servicing the high-voltage system, establish a buffer zone per the specified procedure. Failure to follow this instruction may result in serious personal injury or death. WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious personal injury or death. WARNING: Depower the high-voltage traction battery (HVTB) before carrying out any removal or installation procedures affecting the high-voltage battery system. Failure to follow this instruction may result in serious personal injury or death. WARNING: Wear high-voltage insulated safety gloves and a face shield when working with high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate safety and protection rating. Inspect the gloves before use and always wear them with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to follow these instructions may result in serious personal injury or death. - Ignition OFF. - Disconnect: BCM C4227a. - Ignition ON. - Measure the voltage between the BCM, harness side and ground as follows: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2604 - Are the voltages greater than 10 volts? Yes GO to I2. No VERIFY the Battery Junction Box (BJB) fuse 8 (10A), fuse 26 (20A), and fuse 15 (50A) are OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- I2 CHECK THE BCM GROUNDS - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the BCM, harness side and ground as follows: Are the resistances less than 5 ohms? Yes GO to I3. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- I3 CHECK THE HS-CAN CIRCUITS BETWEEN THE BCM AND THE DLC FOR AN OPEN - Measure the resistance between the BCM C4227a-29, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2605 - Measure the resistance between the BCM C4227a-28, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to I4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- I4 CHECK FOR CORRECT BCM OPERATION NOTE: Do not disconnect the high voltage cables or connectors in the following step. - Disconnect the BCM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect the BCM connectors and make they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new High Voltage Traction Battery (HVTB). CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Pinpoint Test J: The Smart Junction Box (SJB) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test J: The Smart Junction Box (SJB) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 10 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Grounds for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 13 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Power Distribution/SJB for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Smart Junction Box (SJB) communicates with the scan tool through the Medium Speed Controller Area Network (MS-CAN). Circuits VDB06 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2606 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the SJB. Voltage for the SJB is provided directly from the internal SJB busbar through SJB fuse 5 (10A). Ground is provided by circuit GD182 (BK/GY). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - SJB PINPOINT TEST J: THE SJB DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- J1 CHECK THE SJB FUSE FOR VOLTAGE - Ignition OFF. - Measure the voltage between the back of the SJB fuse 5 (10A) terminals (both sides) and ground. - Are the voltages greater than 10 volts? Yes GO to J2. No VERIFY the Smart Junction Box (SJB) fuse 5 (10A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- J2 CHECK THE SJB GROUND CIRCUIT FOR AN OPEN - Disconnect: Negative Battery Cable. - Disconnect: SJB C2280d. - Measure the resistance between the SJB C2280d-8, circuit GD182 (BK/GY), harness side and ground; and between the SJB C2280d-12, circuit GD182 (BK/GY), harness side and ground. Are the resistances less than 5 ohms? Yes Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2607 GO to J3. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- J3 CHECK THE MS-CAN CIRCUITS BETWEEN THE SJB AND THE DLC FOR AN OPEN - Disconnect: SJB C2280b. - Measure the resistance between the SJB C2280b-37, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the SJB C2280b-38, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to J4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- J4 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: - corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test K: The Audio Control Module (ACM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2608 Pinpoint Test K: The Audio Control Module (ACM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 130 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Audio System/Navigation for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Audio Control Module (ACM) communicates with the scan tool through the Medium Speed Controller Area Network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the ACM. Voltage for the ACM is provided by circuit SBP39 (WH/RD). Ground is provided by circuit GD115 (BK/GY). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - ACM PINPOINT TEST K: THE ACM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- K1 CHECK THE ACM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: ACM C240a. - Ignition ON. - Measure the voltage between the ACM C240a-1, circuit SBP39 (WH/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to K2. No VERIFY the Smart Junction Box (SJB) fuse 39 (20A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- K2 CHECK THE ACM GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the ACM C240a-13, circuit GD115 (BK/GY), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2609 - Is the resistance less than 5 ohms? Yes GO to K3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- K3 CHECK THE MS-CAN CIRCUITS BETWEEN THE ACM AND THE DLC FOR AN OPEN - Disconnect: ACM C240b. - Measure the resistance between the ACM C240b-15, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the ACM C240b-16, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to K4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- K4 CHECK FOR CORRECT ACM OPERATION - Disconnect all the ACM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the ACM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new ACM. CLEAR the DTCs. REPEAT the network test with the scan tool. No Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2610 The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test L: The HVAC Module Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test L: The HVAC Module Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 55 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Automatic Climate Control System for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The HVAC module communicates with the scan tool through the Medium Speed Controller Area Network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the HVAC module. Voltage to the HVAC module is provided by circuit SBP15 (WH/RD) and circuit CBP37 (WH). Ground is provided by circuit GD114 (BK/BU). NOTE: The Electronic Manual Temperature Control (EMTC) HVAC module does not communicate with the scan tool. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - HVAC module PINPOINT TEST L: THE HVAC MODULE DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- L1 CHECK THE HVAC MODULE VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: HVAC Module C2356a (DATC) or C2357a (EMTC). - Ignition ON. - Measure the voltage between the HVAC module C2356a-12 or C2357a-12, circuit CBP37 (WH), harness side and ground and between the HVAC module C2356a-13 or C2357a-13, circuit SBP15 (WH/RD) harness side and ground. - Are the voltages greater than 10 volts? Yes GO to L2. No VERIFY the Smart Junction Box (SJB) fuse 15 (10A) or fuse 37 (10A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2611 Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- L2 CHECK THE HVAC MODULE GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the HVAC module C2356a-23 or C2357a-23, circuit GD114 (BK/BU), harness side and ground. Is the resistance less than 5 ohms? Yes GO to L3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- L3 CHECK THE MS-CAN CIRCUITS BETWEEN THE HVAC MODULE AND THE DLC FOR AN OPEN - Measure the resistance between the HVAC module C2356a-25 or C2357a-25, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the HVAC module C2356a-26 or C2357a-26, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to L4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- L4 CHECK FOR CORRECT HVAC MODULE OPERATION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2612 - Disconnect all the HVAC module connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the HVAC module connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new HVAC module. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test M: The Satellite Digital Audio Receiver System (SDARS) Module Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test M: The Satellite Digital Audio Receiver System (SDARS) Module Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 130 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Audio System for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Satellite Digital Audio Receiver System (SDARS) module communicates with the scan tool through the Medium Speed Controller Area Network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the SDARS module. Voltage to the SDARS module is provided by circuit SBP14 (BN/RD). Ground is provided by circuit GD115 (BK/GY). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - SDARS module PINPOINT TEST M: THE SDARS MODULE DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- M1 CHECK THE SDARS MODULE VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: SDARS Module C3290. - Ignition ON. - Measure the voltage between the SDARS module C3290-9, circuit SBP14 (BN/RD), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2613 - Is the voltage greater than 10 volts? Yes GO to M2. No VERIFY the Smart Junction Box (SJB) fuse 14 (10A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- M2 CHECK THE SDARS MODULE GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the SDARS module C3290-3, circuit GD115 (BK/GY), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to M3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- M3 CHECK THE MS-CAN CIRCUITS BETWEEN THE SDARS MODULE AND THE DLC FOR AN OPEN - Measure the resistance between the SDARS module C3290-1, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the SDARS module C3290-7, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2614 - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to M4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- M4 CHECK FOR CORRECT SDARS MODULE OPERATION - Disconnect all the SDARS module connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SDARS module connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SDARS module. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test N: The Front Display Interface Module (FDIM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test N: The Front Display Interface Module (FDIM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 130 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Audio System/Navigation for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Front Display Interface Module (FDIM) communicates with the scan tool through the Medium Speed Controller Area Network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the front display interface module. Voltage to the FDIM is provided by circuit SBP14 (BN/RD). Ground is provided by circuit GD114 (BK/BU). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - FDIM Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2615 PINPOINT TEST N: THE FDIM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- N1 CHECK THE FDIM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: FDIM C2123. - Ignition ON. - Measure the voltage between the FDIM C2123-12, circuit SBP14 (BN/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to N2. No VERIFY the Smart Junction Box (SJB) fuse 14 (10A) is OK. If OK, REPAIR the circuit. CLEAR the DTCs. REPEAT the network test with the scan tool. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- N2 CHECK THE FDIM GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the FDIM C2123-8, circuit GD114 (BK/BU), harness side and ground. Is the resistance less than 5 ohms? Yes GO to N3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- N3 CHECK THE MS-CAN CIRCUITS BETWEEN THE FDIM AND THE DLC FOR AN OPEN - Measure the resistance between the FDIM C2123-4, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2616 harness side. - Measure the resistance between the FDIM C2123-5, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to N4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- N4 CHECK FOR CORRECT FDIM OPERATION - Disconnect the FDIM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the FDIM connector and make sure it seats correctly. - Operate the system and verify the concern is still present. Is the concern still present? Yes INSTALL a new FDIM. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test O: The Front Controls Interface Module (FCIM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test O: The Front Controls Interface Module (FCIM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2617 Refer to Wiring Diagram Set 130 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Audio System/Navigation for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Front Controls Interface Module (FCIM) communicates with the scan tool through the Medium Speed Controller Area Network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the FCIM. Voltage to the FCIM is provided by circuit SBP14 (BN/RD). Ground is provided by circuit GD115 (BK/GY). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - FCIM PINPOINT TEST O: THE FCIM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- O1 CHECK THE FCIM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: FCIM C2402. - Ignition ON. - Measure the voltage between the FCIM C2402-1, circuit SBP14 (BN/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to O2. No VERIFY the Smart Junction Box (SJB) fuse 14 (10A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- O2 CHECK THE FCIM GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the FCIM C2402-2, circuit GD115 (BK/GY), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2618 - Is the resistance less than 5 ohms? Yes GO to O3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- O3 CHECK THE MS-CAN CIRCUITS BETWEEN THE FCIM AND THE DLC FOR AN OPEN - Measure the resistance between the FCIM C2402-3, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the FCIM C2402-4, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to O4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- O4 CHECK FOR CORRECT FCIM OPERATION - Disconnect the FCIM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the FCIM connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2619 Yes INSTALL a new FCIM. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test P: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test P: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Accessory Protocol Interface Module (APIM) communicates with the scan tool through the High Speed Controller Area Network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the HS-CAN connection to the APIM. Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the MS-CAN connection to the APIM. Voltage for the APIM is provided by circuit SBP14 (BN/RD). Circuit GD103 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - APIM PINPOINT TEST P: THE APIM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- P1 CHECK THE APIM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Disconnect: APIM C3338. - Ignition ON. - Measure the voltage between the APIM C3338-1, circuit SBP14 (BN/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to P2. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2620 No VERIFY the SJB fuse 13 (15A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- P2 CHECK THE APIM GROUND CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the APIM C3338-37, circuit GD115 (BK/GY), harness side and ground; and between the APIM C3338-38, circuit GD115 (BK/GY), harness side and ground. - Are the resistances less than 5 ohms? Yes GO to P3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- P3 CHECK THE HS-CAN CIRCUITS BETWEEN THE APIM AND THE DLC FOR AN OPEN - Measure the resistance between the APIM C3338-53, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the APIM C3338-54, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances less than 5 ohms? Yes GO to P4. No Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2621 REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- P4 CHECK THE MS-CAN CIRCUITS BETWEEN THE APIM AND THE DLC FOR AN OPEN - Measure the resistance between the APIM C3338-16, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the APIM C3338-17, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to P5. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- P5 CHECK FOR CORRECT APIM OPERATION - Disconnect the APIM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the APIM connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new APIM. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test Q: The Parking Aid Module (PAM) Does Not Respond To The Scan Tool Or No ISO 9141 Network Communication Communications Network Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2622 Pinpoint Tests Pinpoint Test Q: The Parking Aid Module (PAM) Does Not Respond To The Scan Tool or No ISO 9141 network communication Normal Operation The Parking Aid Module (PAM) communicates with the scan tool through the ISO 9141 communications network, circuit VDB10 (GY). The PAM is the only module which communicates on the ISO 9141. Voltage for the PAM is provided by circuit CBP35 (YE/GY). Ground is provided by circuit GD182 (BK/GY). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - PAM PINPOINT TEST Q: THE PAM DOES NOT RESPOND TO THE SCAN TOOL OR NO ISO 9141 NETWORK COMMUNICATION NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- Q1 CHECK THE DLC PINS FOR DAMAGE NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and verification before proceeding with the Pinpoint Test. See: Initial Inspection and Diagnostic Overview/Communications Network/Inspection And Verification - Ignition OFF. - Disconnect the scan tool cable from the DLC. - Inspect the DLC pin 7 for damage. - Is the DLC pin 7 OK? Yes GO to Q2. No REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q2 CHECK THE PAM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Disconnect: PAM C4014. - Ignition ON. - Measure the voltage between the PAM C4014-1, circuit CBP35 (YE/GY), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2623 - Is the voltage greater than 10 volts? Yes GO to Q3. No VERIFY the Smart Junction Box (SJB) fuse 35 (10A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q3 CHECK THE ISO 9141 CIRCUIT FOR A SHORT TO VOLTAGE - Measure the voltage between the DLC C251-7, circuit VDB10 (GY), harness side and ground. - Is any voltage present? Yes REPAIR the circuit. CLEAR the DTCs. REPEAT the network test with the scan tool. No GO to Q4. ------------------------------------------------- Q4 CHECK THE PAM GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the PAM C4014-4, circuit GD182 (BK/GY), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to Q5. No Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2624 REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q5 CHECK THE ISO 9141 CIRCUIT FOR A SHORT TO GROUND - Measure the resistance between the DLC C251-7, circuit VDB10 (GY), harness side and ground. - Is the resistance greater than 10,000 ohms? Yes GO to Q6. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q6 CHECK THE ISO 9141 COMMUNICATIONS NETWORK CIRCUIT BETWEEN THE PAM AND THE DLC FOR AN OPEN - Measure the resistance between the PAM C4014-8, circuit VDB10 (GY), harness side and the DLC C251-7, circuit VDB10 (GY), harness side. - Is the resistance less than 5 ohms? Yes CONNECT the negative battery cable. GO to Q7. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q7 CHECK FOR CORRECT PAM OPERATION - Disconnect the PAM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the PAM connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new PAM. CLEAR the DTCs. REPEAT the network test with the scan tool. No Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2625 The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test R: Intermittent No High Speed Controller Area Network (HS-CAN) Communication, Communication Can Be Intermittently Communications Network Pinpoint Tests Pinpoint Test R: Intermittent No High Speed Controller Area Network (HS-CAN) Communication, Communication Can Be Intermittently Established Normal Operation The High Speed Controller Area Network (HS-CAN) uses an unshielded twisted pair cable, circuits VDB04 (WH/BU) and VDB05 (WH). In the event that 1 of the 2 network circuits (HS-CAN + or HS-CAN -) becomes open to a module on the network, unreliable network communication to all modules on the network may result. - 4X4 control module (if equipped) - ABS module - Accessory Protocol Interface Module (APIM) - Instrument Cluster (IC) - Occupant Classification System Module (OCSM) - PCM - Power Steering Control Module (PSCM) - Restraints Control Module (RCM) - Battery Control Module (BCM) (Hybrid only) - Transmission Control Module (TCM) (Hybrid only) This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors PINPOINT TEST R: INTERMITTENT NO HS-CAN COMMUNICATION, COMMUNICATION CAN BE INTERMITTENTLY ESTABLISHED NOTE: Various modules will set network DTCs during this test procedure. Clear the DTCs from all modules after the diagnostic procedure is complete. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- R1 CHECK THE DLC PINS FOR DAMAGE - Ignition OFF. - Disconnect the scan tool cable from the DLC. - Inspect DLC pins 6 and 14 for damage. - Are DLC pins 6 and 14 OK? Yes GO to R2. No REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2626 ------------------------------------------------- R2 CHECK THE HS-CAN TERMINATION RESISTANCE - Disconnect: Negative Battery Cable. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance between 54 and 66 ohms? Yes GO to R3. No Go To Pinpoint Test S. See: Pinpoint Test S: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------- R3 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the battery negative cable. GO to R4. No Go To Pinpoint Test S. See: Pinpoint Test S: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------- R4 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO VOLTAGE - Ignition ON. - Measure the voltage between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Is the voltage greater than 6 volts? Yes REPAIR the circuit. CLEAR the DTCs. REPEAT the network test with the scan tool. No Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2627 GO to R5. ------------------------------------------------- R5 CHECK FOR RESTORED COMMUNICATION WITH THE PCM DISABLED NOTE: An Integrated Diagnostic System (IDS) session must be established prior to disabling the PCM in this test step. If the PCM has failed communication during multiple attempts to identify the vehicle, first identify the vehicle manually by entering a PCM part number, calibration number or tear tag when prompted by IDS. NOTE: When a vehicle is manually identified by a PCM part number, calibration number or tear tag, the IDS will not automatically run a network test. The network test must be manually selected and run. NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: Battery Junction Box (BJB) Fuses 5 (10A) and 29 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes Go To Pinpoint Test A. See: Pinpoint Test A: The PCM Does Not Respond To The Scan Tool No For Escape Hybrid and Mariner Hybrid, INSTALL the removed fuses. GO to R6. For Escape and Mariner, INSTALL the removed fuses. GO to R7. ------------------------------------------------- R6 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE BCM DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: BJB Fuses 26 (20A) and 8 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuse. Go To Pinpoint Test I. See: Pinpoint Test I: The Battery Control Module (BCM) Does Not Respond To The Scan Tool No INSTALL the removed fuse. GO to R7. ------------------------------------------------- R7 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE PSCM AND 4X4 CONTROL MODULE (IF EQUIPPED) DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: SJB Fuse 35 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes If the vehicle is not equipped with a 4X4 control module, INSTALL the removed fuses. Go To Pinpoint Test G. See: Pinpoint Test G: The Power Steering Control Module (PSCM) Does Not Respond To The Scan Tool Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2628 If the vehicle is equipped with a 4X4 control module, INSTALL the removed fuses. GO to R8. No INSTALL the removed fuse. GO to R9. ------------------------------------------------- R8 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE 4X4 CONTROL MODULE DISCONNECTED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: 4X4 Control Module C3184. - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes CONNECT the 4x4 control module. Go To Pinpoint Test C. See: Pinpoint Test C: The 4X4 Control Module Does Not Respond To The Scan Tool No CONNECT the 4x4 control module. Go To Pinpoint Test G. See: Pinpoint Test G: The Power Steering Control Module (PSCM) Does Not Respond To The Scan Tool ------------------------------------------------- R9 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE RCM DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: SJB Fuse 31 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuse. Go To Pinpoint Test E. See: Pinpoint Test E: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool No INSTALL the removed fuse. GO to R10. ------------------------------------------------- R10 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE OCSM DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: SJB Fuse 46 (7.5A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuse. Go To Pinpoint Test F. See: Pinpoint Test F: The Occupant Classification System Module (OCSM) Does Not Respond To The Scan Tool No GO to R11. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2629 ------------------------------------------------- R11 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE IC DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: SJB Fuses 26 (10A), 29 (5A) and 43 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuses. Go To Pinpoint Test D. See: Pinpoint Test D: The Instrument Cluster (IC) Does Not Respond To The Scan Tool No If the vehicle is equipped with an Accessory Protocol Interface Module (APIM), INSTALL the removed fuses. GO to R12. If the vehicle is not equipped with an APIM, INSTALL the removed fuses. GO to R13. ------------------------------------------------- R12 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE APIM DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: SJB Fuse 3 (15A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuse. Go To Pinpoint Test P. See: Pinpoint Test P: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool No GO to R13. ------------------------------------------------- R13 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE ABS MODULE DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: SJB Fuse 34 (5A) (Escape and Mariner) or Fuse 27 (10A) (Hybrid). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuse. Go To Pinpoint Test B. See: Pinpoint Test B: The ABS Module Does Not Respond To The Scan Tool No If the vehicle is not a Hybrid Electric Vehicle (HEV), INSTALL the removed fuse. An intermittent fault is not present. Go To Pinpoint Test S. See: Pinpoint Test S: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding If the vehicle is an HEV, INSTALL the removed fuse. GO to R14. ------------------------------------------------- R14 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE HEV TCM DISABLED Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2630 NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: BJB Fuses 5 (10A) and 24 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuses. Go To Pinpoint Test H. See: Pinpoint Test H: The Transmission Control Module (TCM) Does Not Respond To The Scan Tool No INSTALL the removed fuses. An intermittent fault is not present. Go To Pinpoint Test S. See: Pinpoint Test S: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------S1-S20 Communications Network Pinpoint Tests Pinpoint Test S: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 23 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Electronic Engine Controls - 2.5L for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The High Speed Controller Area Network (HS-CAN) uses an unshielded twisted pair cable, circuits VDB04 (WH/BU) and VDB05 (WH). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - 4X4 control module (if equipped) - ABS module - Accessory Protocol Interface Module (APIM) (if equipped) - Instrument Cluster (IC) - Occupant Classification System Module (OCSM) - PCM - Power Steering Control Module (PSCM) - Restraints Control Module (RCM) - Battery Control Module (BCM) (Hybrid only) - Transmission Control Module (TCM) (Hybrid only) PINPOINT TEST S: NO HS-CAN COMMUNICATION, ALL MODULES ARE NOT RESPONDING NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and verification before proceeding with the pinpoint test. See: Initial Inspection and Diagnostic Overview/Communications Network/Inspection And Verification NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- S1 CHECK THE DLC PINS FOR DAMAGE Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2631 - Ignition OFF. - Inspect DLC pins 6 and 14 for damage. - Are DLC pins 6 and 14 OK? Yes GO to S2. No REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S2 CHECK THE HS-CAN TERMINATION RESISTANCE - Disconnect: Negative Battery Cable. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance between 54 and 66 ohms? Yes GO to S3. No GO to S5. ------------------------------------------------- S3 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S4. No GO to S21. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2632 S4 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO VOLTAGE - Ignition ON. - Measure the voltage between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Is the voltage greater than 6 volts? Yes REPAIR the circuit. CLEAR the DTCs. REPEAT the network test with the scan tool. No The HS-CAN has tested within specifications. Go To Pinpoint Test R to test for an intermittent network fault condition. See: Pinpoint Test R: Intermittent No High Speed Controller Area Network (HS-CAN) Communication, Communication Can Be Intermittently ------------------------------------------------- S5 CHECK THE HS-CAN TERMINATION RESISTOR - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance between 108 and 132 ohms? Yes GO to S6. No GO to S9. ------------------------------------------------- S6 CHECK THE HS-CAN TERMINATION RESISTOR WITH THE PCM DISCONNECTED - Disconnect: PCM C175b. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance between 108 and 132 ohms? Yes GO to S7. No Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2633 GO to S8. ------------------------------------------------- S7 CHECK THE HS-CAN CIRCUITS BETWEEN THE PCM AND THE DLC FOR AN OPEN - Measure the resistance between the PCM C175b-59, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the PCM C175b-58, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to S31. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S8 CHECK THE HS-CAN CIRCUITS BETWEEN THE IC AND THE DLC FOR AN OPEN - Disconnect: IC C220. - Measure the resistance between the IC C220-15, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the IC C220-14, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances less than 5 ohms? Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2634 Yes CONNECT the negative battery cable. GO to S37. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S9 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes GO to S11. No GO to S10. ------------------------------------------------- S10 CHECK THE HS-CAN CIRCUITS FOR AN OPEN AT THE DLC - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance greater than 10,000 ohms? Yes REPAIR the DLC or REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. No A capacitor internal to a module may still be draining causing irregular resistance readings. WAIT 5 minutes. REPEAT the pinpoint test. ------------------------------------------------- S11 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE PCM DISCONNECTED - Disconnect: PCM C175b. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2635 - Is the resistance less than 5 ohms? Yes GO to S12. No CONNECT the negative battery cable. GO to S31. ------------------------------------------------- S12 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE ABS MODULE DISCONNECTED - Disconnect: ABS Module C155 . - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes If the vehicle is equipped with a 4X4 control module, GO to S13. If the vehicle is not equipped with a 4X4 control module, GO to S14. No CONNECT the negative battery cable. GO to S32. ------------------------------------------------- S13 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE 4X4 CONTROL MODULE DISCONNECTED - Disconnect: 4X4 Control Module C3184. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes GO to S14. No CONNECT the negative battery cable. GO to S33. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2636 S14 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE RCM DISCONNECTED - Disconnect: RCM C2041b. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes GO to S15. No CONNECT the negative battery cable. GO to S34. ------------------------------------------------- S15 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE OCSM DISCONNECTED - Disconnect: OCSM C3285. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes If the vehicle is equipped with an Accessory Protocol Interface Module (APIM), GO to S16. If the vehicle is not equipped with an APIM, GO to S17. No CONNECT the negative battery cable. GO to S35. ------------------------------------------------ S16 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE APIM DISCONNECTED - Disconnect: APIM C3338. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes GO to S17. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2637 No CONNECT the negative battery cable. GO to S36. ------------------------------------------------- S17 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE IC DISCONNECTED - Disconnect: IC C220. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes GO to S18. No CONNECT the negative battery cable. GO to S37. ------------------------------------------------- S18 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE PSCM DISCONNECTED - Disconnect: PSCM C1463a (Escape and Mariner) or C2231a (Hybrid). - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes If the vehicle is a Hybrid Electric Vehicle (HEV), GO to S19. If the vehicle is not an HEV, REPAIR the circuit. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. No CONNECT the negative battery cable. GO to S38. ------------------------------------------------- S19 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE TCM DISCONNECTED - Disconnect: TCM C1458a. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2638 - Is the resistance less than 5 ohms? Yes GO to S20. No CONNECT the negative battery cable. GO to S39. ------------------------------------------------- S20 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE BCM DISCONNECTED WARNING: When servicing the high-voltage system, establish a buffer zone per the specified procedure. Failure to follow this instruction may result in serious personal injury or death. WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious personal injury or death. WARNING: Depower the high-voltage traction battery (HVTB) before carrying out any removal or installation procedures affecting the high-voltage battery system. Failure to follow this instruction may result in serious personal injury or death. WARNING: Wear high-voltage insulated safety gloves and a face shield when working with high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate safety and protection rating. Inspect the gloves before use and always wear them with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to follow these instructions may result in serious personal injury or death. - Disconnect: BCM C4227a. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. No CONNECT the negative battery cable. GO to S40. -----------------------------------------------S21-S40 Communications Network Pinpoint Tests Pinpoint Test S: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2639 Refer to Wiring Diagram Set 23 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Electronic Engine Controls - 2.5L for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The High Speed Controller Area Network (HS-CAN) uses an unshielded twisted pair cable, circuits VDB04 (WH/BU) and VDB05 (WH). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - 4X4 control module (if equipped) - ABS module - Accessory Protocol Interface Module (APIM) (if equipped) - Instrument Cluster (IC) - Occupant Classification System Module (OCSM) - PCM - Power Steering Control Module (PSCM) - Restraints Control Module (RCM) - Battery Control Module (BCM) (Hybrid only) - Transmission Control Module (TCM) (Hybrid only) PINPOINT TEST S: NO HS-CAN COMMUNICATION, ALL MODULES ARE NOT RESPONDING NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and verification before proceeding with the pinpoint test. See: Initial Inspection and Diagnostic Overview/Communications Network/Inspection And Verification NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- S21 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE PCM DISCONNECTED - Disconnect: PCM C175b. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S31. No GO to S22. ------------------------------------------------- S22 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE ABS MODULE DISCONNECTED - Disconnect: ABS Module C155. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2640 - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S32. No If the vehicle is equipped with a 4X4 control module, GO to S23. If the vehicle is not equipped with a 4X4 control module, GO to S24. ------------------------------------------------- S23 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE 4X4 CONTROL MODULE DISCONNECTED - Disconnect: 4X4 Control Module C3184. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S33. No GO to S24. ------------------------------------------------- S24 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE RCM DISCONNECTED - Disconnect: RCM C2041b. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S34. No GO to S25. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2641 S25 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE OCSM DISCONNECTED - Disconnect: OCSM C3285. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S35. No If the vehicle is equipped with an Accessory Protocol Interface Module (APIM), GO to S26. If the vehicle is not equipped with an APIM, GO to S27. ------------------------------------------------- S26 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE APIM DISCONNECTED - Disconnect: APIM C3338. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S36. No GO to S27. ------------------------------------------------- S27 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE IC DISCONNECTED - Disconnect: IC C220. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S37. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2642 No GO to S28. ------------------------------------------------- S28 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE PSCM DISCONNECTED - Disconnect: PSCM C1463a (Escape and Mariner) or C2231a (Hybrid). - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S38. No If the vehicle is a Hybrid Electric Vehicle (HEV), GO to S29. If the vehicle is not an HEV, REPAIR the circuit. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S29 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE TCM DISCONNECTED - Disconnect: TCM C1458a. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S39. No GO to S30. ------------------------------------------------- S30 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE BCM DISCONNECTED WARNING: When servicing the high-voltage system, establish a buffer zone per the specified procedure. Failure to follow this instruction may result in serious personal injury or death. WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious personal injury or death. WARNING: Depower the high-voltage traction battery (HVTB) before carrying out any removal or installation procedures affecting the high-voltage battery system. Failure to follow this instruction may result in serious personal injury or death. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2643 WARNING: Wear high-voltage insulated safety gloves and a face shield when working with high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate safety and protection rating. Inspect the gloves before use and always wear them with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to follow these instructions may result in serious personal injury or death. - Disconnect: BCM C4227a. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S40. No REPAIR the circuit. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S31 CHECK FOR CORRECT PCM OPERATION - Disconnect all the PCM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the PCM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new PCM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S32 CHECK FOR CORRECT ABS MODULE OPERATION - Disconnect the ABS module connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the ABS module connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new ABS module. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2644 the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S33 CHECK FOR CORRECT 4X4 CONTROL MODULE OPERATION - Disconnect the 4X4 control module connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the 4X4 control module connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new 4X4 control module. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S34 CHECK FOR CORRECT RCM OPERATION - Disconnect all the RCM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the RCM connectors and make sure they seat correctly. - Verify the concern is still present. - Is the concern still present? Yes INSTALL a new RCM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S35 CHECK FOR CORRECT OCSM OPERATION - Disconnect the OCSM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the OCSM connector and make sure it seats correctly. - Verify the concern is still present. - Is the concern still present? Yes INSTALL a new OCSM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2645 ------------------------------------------------- S36 CHECK FOR CORRECT APIM OPERATION - Disconnect the APIM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the APIM connector and make sure it seats correctly. - Verify the concern is still present. - Is the concern still present? Yes INSTALL a new APIM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. REPOWER the SRS. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S37 CHECK FOR CORRECT IC OPERATION - Disconnect the IC connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the IC connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new IC. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S38 CHECK FOR CORRECT PSCM OPERATION - Disconnect all the PSCM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the PSCM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new steering column assembly. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S39 CHECK FOR CORRECT TCM OPERATION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2646 - Disconnect the TCM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the TCM and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new TCM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S40 CHECK FOR CORRECT BCM OPERATION NOTE: Do not disconnect the high voltage cables or connectors in the following step. - Disconnect the BCM low voltage connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect the BCM low voltage connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new High Voltage Traction Battery (HVTB). CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Pinpoint Test T: Intermittent No Medium Speed Controller Area Network (MS-CAN) Communication, Communication Can Be Intermittent Communications Network Pinpoint Tests Pinpoint Test T: Intermittent No Medium Speed Controller Area Network (MS-CAN) Communication, Communication Can Be Intermittently Established Normal Operation The Medium Speed Controller Area Network (MS-CAN) uses an unshielded twisted pair cable. Circuits VDB06 (GY/OG) and VDB07 (VT/OG) provide the network connection to all modules on the network. In the event that 1 of the 2 network circuits (MS-CAN + or MS-CAN -) becomes open to a module on the network, unreliable network communication to all modules on the network may result. The following modules communicate with the scan tool using the MS-CAN: - Audio Control Module (ACM) - Accessory Protocol Interface Module (APIM) - Front Controls Interface Module (FCIM) - Front Display Interface Module (FDIM) - HVAC module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2647 - Instrument Cluster (IC) - Satellite Digital Audio Receiver System (SDARS) module - Smart Junction Box (SJB) This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors PINPOINT TEST T: INTERMITTENT NO MS-CAN COMMUNICATION, COMMUNICATION CAN BE INTERMITTENTLY ESTABLISHED NOTE: Various modules will set network DTCs during this test procedure. Clear DTCs from all modules after the diagnostic procedure is completed. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- T1 CHECK THE DLC PINS FOR DAMAGE - Ignition OFF. - Disconnect the scan tool cable from the DLC. - Inspect DLC pins 3 and 11 for damage. - Are DLC pins 3 and 11 OK? Yes GO to T2. No REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- T2 CHECK THE MS-CAN TERMINATION RESISTANCE - Disconnect: Negative Battery Cable. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance between 54 and 66 ohms? Yes GO to T3. No Go To Pinpoint Test U. See: Pinpoint Test U: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------- T3 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2648 VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to T4. No Go To Pinpoint Test U. See: Pinpoint Test U: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------- T4 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO VOLTAGE - Ignition ON. - Measure the voltage between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Is the voltage greater than 6 volts? Yes REPAIR the circuit. CLEAR the DTCs. REPEAT the network test with the scan tool. No GO to T5. ------------------------------------------------- T5 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE SJB DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: SJB Fuse 5 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuse. Go To Pinpoint Test J. See: Pinpoint Test J: The Smart Junction Box (SJB) Does Not Respond To The Scan Tool No INSTALL the removed fuse. GO to T6. ------------------------------------------------- T6 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE HVAC MODULE DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2649 - Disconnect: SJB Fuses 37 (10A) and 15 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuses. Go To Pinpoint Test L. See: Pinpoint Test L: The HVAC Module Does Not Respond To The Scan Tool No INSTALL the removed fuses. GO to T7. ------------------------------------------------- T7 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE ACM DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: SJB Fuse 39 (20A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuse. Go To Pinpoint Test K. See: Pinpoint Test K: The Audio Control Module (ACM) Does Not Respond To The Scan Tool No If the vehicle is equipped with an Accessory Protocol Interface Module (APIM), INSTALL the removed fuse. GO to T8. If the vehicle is not equipped with an APIM, INSTALL the removed fuse. GO to T9. ------------------------------------------------- T8 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE APIM DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: SJB Fuse 3 (15A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuses. Go To Pinpoint Test P. See: Pinpoint Test P: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool No INSTALL the removed fuses. GO to T9. ------------------------------------------------- T9 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE FCIM, FDIM AND/OR SDARS MODULE DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: SJB Fuse 14 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2650 Yes For vehicles equipped with an FDIM only, INSTALL the removed fuse. Go To Pinpoint Test N. See: Pinpoint Test N: The Front Display Interface Module (FDIM) Does Not Respond To The Scan Tool For vehicles also equipped with an FCIM and/or a SDARS module, INSTALL the removed fuse. GO to T10. No INSTALL the removed fuse. GO to T13. ------------------------------------------------- T10 VERIFY VEHICLE EQUIPMENT - FCIM - Inspect the vehicle for an FCIM. - Is the vehicle equipped with an FCIM? Yes GO to T11. No GO to T12. ------------------------------------------------- T11 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE FCIM DISCONNECTED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: FCIM C2402. - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes CONNECT the FCIM. Go To Pinpoint Test O. See: Pinpoint Test O: The Front Controls Interface Module (FCIM) Does Not Respond To The Scan Tool No CONNECT the FCIM. GO to T12. ------------------------------------------------- T12 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE SDARS MODULE DISCONNECTED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: SDARS Module C3290. - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. Do all other modules pass the network test? Yes CONNECT the SDARS module. Go To Pinpoint Test M. See: Pinpoint Test M: The Satellite Digital Audio Receiver System (SDARS) Module Does Not Respond To The Scan Tool No CONNECT the SDARS module. Go To Pinpoint Test N. See: Pinpoint Test N: The Front Display Interface Module (FDIM) Does Not Respond To The Scan Tool Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2651 ------------------------------------------------- T13 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE IC DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: SJB Fuses 26 (10A), 29 (5A) and 43 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuses. Go To Pinpoint Test D. See: Pinpoint Test D: The Instrument Cluster (IC) Does Not Respond To The Scan Tool No INSTALL the removed fuses. An intermittent fault is not present. Go To Pinpoint Test U. See: Pinpoint Test U: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------Pinpoint Test U: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding Communications Network Pinpoint Tests Pinpoint Test U: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Medium Speed Controller Area Network (MS-CAN) uses an unshielded twisted pair cable. Circuits VDB06 (GY/OG) and VDB07 (VT/OG) provide the network connection to all modules on the network. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Audio Control Module (ACM) - Accessory Protocol Interface Module (APIM) - Front Controls Interface Module (FCIM) - Front Display Interface Module (FDIM) - HVAC module - Instrument Cluster (IC) - Satellite Digital Audio Receiver System (SDARS) module - Smart Junction Box (SJB) PINPOINT TEST U: PINPOINT TEST U: NO MS-CAN COMMUNICATION, ALL MODULES ARE NOT RESPONDING NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and verification before proceeding with the Pinpoint Test. See: Initial Inspection and Diagnostic Overview/Communications Network/Inspection And Verification NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- U1 CHECK THE DLC PINS FOR DAMAGE - Ignition OFF. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2652 - Disconnect the scan tool cable from the Data Link Connector (DLC). - Inspect DLC pins 3 and 11 for damage. - Are DLC pins 3 and 11 OK? Yes GO to U2. No REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- U2 CHECK THE MS-CAN TERMINATION RESISTANCE - Disconnect: Negative Battery Cable. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance between 54 and 66 ohms? Yes GO to U3. No GO to U5. ------------------------------------------------- U3 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to U4. No GO to U19. ------------------------------------------------- U4 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO VOLTAGE Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2653 - Ignition ON. - Measure the voltage between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Is the voltage greater than 6 volts? Yes REPAIR the circuit. CLEAR the DTCs. REPEAT the network test with the scan tool. No The CAN has tested within specifications. Go To Pinpoint Test T to diagnose the intermittent MS-CAN fault. See: Pinpoint Test T: Intermittent No Medium Speed Controller Area Network (MS-CAN) Communication, Communication Can Be Intermittent ------------------------------------------------- U5 CHECK THE MS-CAN TERMINATION RESISTOR - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. Is the resistance between 108 and 132 ohms? Yes GO to U6. No GO to U9. ------------------------------------------------- U6 CHECK THE MS-CAN TERMINATION RESISTOR WITH THE SJB DISCONNECTED - Disconnect: Smart Junction Box (SJB) C2280b. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance between 108 and 132 ohms? Yes GO to U7. No GO to U8. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2654 ------------------------------------------------- U7 CHECK THE MS-CAN CIRCUITS BETWEEN THE SJB AND THE DLC FOR AN OPEN - Measure the resistance between the SJB C2280b-37, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the SJB C2280b-38, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to U27. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- U8 CHECK THE MS-CAN CIRCUITS BETWEEN THE IC AND THE DLC FOR AN OPEN - Disconnect: IC C220. - Measure the resistance between the IC C220-2, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the IC C220-1, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2655 CONNECT the negative battery cable. GO to U34. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- U9 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes GO to U11. No GO to U10. ------------------------------------------------- U10 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR AN OPEN - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance greater than 10,000 ohms? Yes REPAIR the DLC or REPAIR the circuit in question. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. No A capacitor internal to a module may still be draining causing irregular resistance readings. WAIT 5 minutes. REPEAT the pinpoint test. ------------------------------------------------- U11 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE SJB DISCONNECTED - Disconnect: SJB C2280b. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2656 Yes If the vehicle is equipped with a Satellite Digital Audio Receiver System (SDARS) module, GO to U12. If the vehicle is not equipped with a SDARS module, GO to U13. No CONNECT the negative battery cable. GO to U27. ------------------------------------------------- U12 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE SDARS MODULE DISCONNECTED - Disconnect: SDARS Module C3290. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes GO to U13. No CONNECT the negative battery cable. GO to U28. ------------------------------------------------- U13 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE FDIM DISCONNECTED - Disconnect: FDIM C2123. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes If the vehicle is equipped with a Front Controls Interface Module (FCIM), GO to U14. If the vehicle is not equipped with an FCIM, GO to U15. No CONNECT the negative battery cable. GO to U29. ------------------------------------------------- U14 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE FCIM DISCONNECTED - Disconnect: FCIM C2402. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2657 - Is the resistance less than 5 ohms? Yes GO to U15. No CONNECT the negative battery cable. GO to U30. ------------------------------------------------- U15 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE ACM DISCONNECTED - Disconnect: ACM C240b. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes If the vehicle is equipped with an APIM, GO to U16. If the vehicle is not equipped with an APIM, GO to U17. No CONNECT the negative battery cable. GO to U31. ------------------------------------------------- U16 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE APIM DISCONNECTED - Disconnect: APIM C3338. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes GO to U17. No CONNECT the negative battery cable. GO to U32. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2658 U17 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE HVAC MODULE DISCONNECTED - Disconnect: HVAC Module C2356a (DATC) or C2357a (EMTC). - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes GO to U18. No CONNECT the negative battery cable. GO to U33. ------------------------------------------------- U18 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE IC DISCONNECTED - Disconnect: IC C220. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes REPAIR the circuit. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. No CONNECT the negative battery cable. GO to U34. ------------------------------------------------- U19 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE SJB DISCONNECTED - Disconnect: SJB C2280b. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to U27. No Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2659 If the vehicle is equipped with a Satellite Digital Audio Receiver System (SDARS) module, GO to U20. If the vehicle is not equipped with a SDARS module, GO to U21. ------------------------------------------------- U20 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE SDARS MODULE DISCONNECTED - Disconnect: SDARS Module C3290. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to U28. No GO to U21. ------------------------------------------------- U21 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE FDIM DISCONNECTED - Disconnect: FDIM C2123. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to U29. No If the vehicle is equipped with a Front Controls Interface Module (FCIM), GO to U22. If the vehicle is not equipped with an FCIM, GO to U23. ------------------------------------------------- U22 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE FCIM DISCONNECTED - Disconnect: FCIM C2402. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2660 - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to U30. No GO to U23. ------------------------------------------------- U23 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE ACM DISCONNECTED - Disconnect: ACM C240b. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to U31. No If the vehicle is equipped with an APIM, GO to U24. If the vehicle is not equipped with an APIM, GO to U25. ------------------------------------------------- U24 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE APIM DISCONNECTED - Disconnect: APIM C3338. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to U32. No GO to U25. ------------------------------------------------- U25 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE HVAC MODULE Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2661 DISCONNECTED - Disconnect: HVAC Module C2356a (DATC) or C2357a (EMTC). - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to U33. No GO to U26. ------------------------------------------------- U26 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE IC DISCONNECTED - Disconnect: IC C220. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to U34. No REPAIR the circuit. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- U27 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2662 ------------------------------------------------- U28 CHECK FOR CORRECT SDARS MODULE OPERATION - Disconnect the SDARS module connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the SDARS module connector and make it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SDARS module. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- U29 CHECK FOR CORRECT FDIM OPERATION - Disconnect the FDIM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the FDIM connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new FDIM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- U30 CHECK FOR CORRECT FCIM OPERATION - Disconnect the FCIM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the FCIM connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new FCIM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- U31 CHECK FOR CORRECT ACM OPERATION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2663 - Disconnect all the ACM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the ACM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new ACM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- U32 CHECK FOR CORRECT APIM OPERATION - Disconnect the APIM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the APIM connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new APIM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- U33 CHECK FOR CORRECT HVAC MODULE OPERATION - Disconnect all the HVAC module connectors. - Check for: - corrosion - damaged pins - pushed-out pins - Connect all the HVAC module connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new HVAC module. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- U34 CHECK FOR CORRECT IC OPERATION - Disconnect the IC connector. - Check for: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2664 - corrosion - damaged pins - pushed-out pins - Connect the IC connector and make sure it seats correctly. - Operate the system and verify the concern is still present. Is the concern still present? Yes INSTALL a new IC. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test V: No Power To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test V: No Power To The Scan Tool Refer to Wiring Diagram Set 14 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The scan tool is connected to the Data Link Connector (DLC) to communicate with the High Speed Controller Area Network (HS-CAN), Medium Speed Controller Area Network (MS-CAN), and ISO 9141 communications network. Voltage for the scan tool is provided by circuit SBP20 (GN/RD). Ground is provided by circuits GD112 (BK/GN) and GD114 (BK/BU). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - DLC PINPOINT TEST V: NO POWER TO THE SCAN TOOL NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and verification before proceeding with the Pinpoint Test. See: Initial Inspection and Diagnostic Overview/Communications Network/Inspection And Verification NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- V1 CHECK DLC PINS FOR DAMAGE - Disconnect the scan tool cable from the DLC. - Inspect the DLC pins 4, 5 and 16 for damage. - Are the DLC pins 4, 5 and 16 OK? Yes GO to V2. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2665 No REPAIR the DLC as necessary. REPEAT the network test with the scan tool. ------------------------------------------------- V2 CHECK THE DLC VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Measure the voltage between the DLC C251-16, circuit SBP20 (GN/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to V3. No VERIFY the Smart Junction Box (SJB) fuse 20 (15A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. REPEAT the network test with the scan tool. ------------------------------------------------- V3 CHECK THE DLC GROUND CIRCUITS FOR AN OPEN - Disconnect: Negative Battery Cable. - Measure the resistance between the DLC C251-4, circuit GD112 (BK/GN), harness side and ground; and between the DLC C251-5, circuit GD114 (BK/BU), harness side and ground. - Are the resistances less than 5 ohms? Yes REPAIR the scan tool. CONNECT the negative battery cable. REPEAT the network test with the scan tool. No REPAIR the circuit in question. CONNECT the negative battery cable. REPEAT the network test with the scan tool. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2666 Information Bus: Programming and Relearning Programmable Module Installation (PMI) PROGRAMMABLE MODULE INSTALLATION Special Tool(s) Special Tool(s) Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For instructions, refer to the specific module removal and installation procedures. 1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. The IDS downloads the data into the new module and displays Module Configuration Complete. 9. Test module for correct operation. Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Not Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Install the new module. 2. Connect the IDS and identify the vehicle as normal. 3. From the Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. If the data is not available, the IDS displays a screen stating to contact the As-Built Data Center. Retrieve the data from the technician service publication website at this time and press the check mark. 9. Enter the module data and press the check mark. 10. The IDS downloads the data into the new module and displays Module Configuration Complete. 11. Test module for correct operation. Accessory Protocol Interface Module (APIM) Programming Accessory Protocol Interface Module (APIM) Programming Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2667 Accessory Protocol Interface Module (APIM) Programming Using the Integrated Diagnostic System (IDS) NOTE: If a new Accessory Protocol Interface Module (APIM) is being installed, install the new APIM before carrying out the following procedure. 1. Turn the Audio Control Module (ACM) on. 2. Connect the scan tool to the Data Link Connector (DLC). 3. Connect one end of the Universal Serial Bus (USB) male-A to male-A cable to the scan tool. 4. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 5. From the technician service publication website, run On-Line Automotive Service Information System (OASIS) using Quick Start or by manually entering the Vehicle Identification Number (VIN). 6. From the OASIS tab, select the "Sync/APIM" bullet. 7. Select the "Read APIM" button to verify the current APIM Vehicle Interface Processor (VIP) and Consumer Interface Processor (CIP) software levels. 8. NOTE: Do not disconnect the Vehicle Communication Module (VCM) or USB cables during APIM programming. Select the desired software level from the list of available software for programming then select the "Program APIM" button to begin the APIM programming process. Enter the APIM As-Built data if prompted. - When the VIP is programmed, the CIP will be programmed automatically. 9. The Sync/APIM application downloads the software into the APIM and displays "Programming has been completed successfully". 10. Test the audio system for correct operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 2668 Information Bus: Service and Repair PROGRAMMABLE MODULE INSTALLATION Special Tool(s) Special Tool(s) Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For instructions, refer to the specific module removal and installation procedures. 1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. The IDS downloads the data into the new module and displays Module Configuration Complete. 9. Test module for correct operation. Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Not Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Install the new module. 2. Connect the IDS and identify the vehicle as normal. 3. From the Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. If the data is not available, the IDS displays a screen stating to contact the As-Built Data Center. Retrieve the data from the technician service publication website at this time and press the check mark. 9. Enter the module data and press the check mark. 10. The IDS downloads the data into the new module and displays Module Configuration Complete. 11. Test module for correct operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2672 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2673 Knock Sensor: Description and Operation Knock Sensor (KS) The KS 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2674 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the intake manifold. 3. Remove the bolt and the Knock Sensor (KS). - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) The MIL alerts the driver that the powertrain control module (PCM) has detected an on board diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD diagnostic trouble code (DTC) is set. - The MIL is located on the instrument cluster and is labeled as International Standards Organization (ISO) engine symbol. - Power is supplied to the MIL whenever the key is in the ON or START position. - The MIL remains on in the on/start mode as a bulb check during the instrument cluster prove-out 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 is set. - the instrument cluster illuminates 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). - If the MIL remains off during the bulb check, there is: an instrument cluster concern. - an instrument cluster wiring concern. - 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 concern. - For any MIL concern, refer to Symptom Charts, GO to Quick Test QT1 See: Testing and Inspection/Symptom Related Diagnostic Procedures/QT : Powertrain Control Module (PCM)/Transaxle Control Module (TCM) Quick Test . - If the MIL blinks at a steady rate, a severe misfire condition may exist. - The MIL flashes after a period of time with the key in the RUN position (engine not running) if DTC P1000 is set. ISO Standard Engine Symbol Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2684 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2685 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor uses a piezo-resistive silicon sensing element to provide a voltage proportional to the absolute pressure in the intake manifold. The MAP sensor is part of the EGR system. The PCM uses information from the MAP, TP, MAF, CHT and CKP sensors to determine how much exhaust gas is introduced into the intake manifold. Typical Manifold Absolute Pressure (MAP) Sensor Manifold Absolute Pressure (MAP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2686 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the Throttle Body (TB). 3. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector. 4. Using a tool like KD Tool #58181 or Lisle T25 Torx Bit, remove the screw and the MAP sensor. - To install, tighten to 3 Nm (27 lb-in). 5. NOTE: Lubricate the MAP sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Oxygen Sensor: Customer Interest Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2695 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Oxygen Sensor: All Technical Service Bulletins Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2701 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2704 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #12 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #12 > Page 2707 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2708 Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) The HO2S 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 voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a 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 a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Typical Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) Universal Heated Oxygen Sensor (HO2S) The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal HO2S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor Exploded View Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page 2711 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S. - Calculate the correct torque wrench setting for the following torque. - To install, tighten to 48 Nm (35 lb-ft). 4. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page 2712 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor Catalyst Monitor Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector. 3. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS. - Calculate the correct torque wrench setting for the following torque. - To install, tighten to 48 Nm (35 lb-ft). 4. NOTE: Apply a light coat of anti-seize lubricant to the threads of the CMS. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation Torque-Based Electronic Throttle Control (ETC) Overview The torque-based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. Electronic Throttle Body (ETB) The ETB has the following characteristics: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires two wires). - An internal spring is used to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore. This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. - The required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. - There is one reference voltage and one signal return circuit between the PCM and the ETB. The reference voltage and the signal return circuits are shared with the reference voltage and signal return circuits used by the accelerator pedal position (APP) sensor. There are also two throttle position (TP) signal circuits for redundancy. The redundant TP signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor For additional information on the APP sensor, refer to Engine Control Components See: Description and Operation/Engine Control Components. Electronic Throttle Control (ETC) System Strategy The torque-based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize the fuel control while delivering the requested torque. The ETC monitor system is distributed across two processors within the PCM: the main powertrain control processor unit (CPU) and a separate monitoring processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, appropriate corrective action is taken. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2717 ECT System Failure Mode Effects Management (FMEM) Electronic Throttle Monitor Operation a Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Accelerator Pedal Position (APP) and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check a Correlation and range/performance - sensor disagreement between processors internal to the PCM. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions See: Testing and Inspection/Diagnostic Trouble Code Descriptions for additional DTC information. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2718 Throttle Position (TP) Sensor Check a Correlation and range/performance - sensor disagreement between processors internal to the PCM, TP inconsistent with requested throttle plate position. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions See: Testing and Inspection/Diagnostic Trouble Code Descriptions for additional DTC information. Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check a Note: For all DTCs, in addition to the MIL, the powertrain malfunction indicator (wrench) is on for the concern that caused the FMEM action. Monitor execution is continuous. Monitor false detection duration is less than 5 seconds to register a concern. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Engine Control Module: Customer Interest Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2727 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0442/P0456/P1450 TSB 10-1-3 02/01/10 HYBRID ONLY - DTCS P0442, P0456 OR P1450 - BUILT ON OR BEFORE 4/6/2009 FORD: 2010 Fusion 2009 Escape MERCURY: 2010 Milan 2009 Mariner This article supersedes TSB 09-9-9 to add a production fix date. ISSUE Some 2009 Escape Hybrid, Mariner Hybrid, 2010 Fusion Hybrid and Milan Hybrid vehicles built on or before 4/6/2009 may exhibit a malfunction indicator light (MIL) accompanied by diagnostic trouble code (DTC) P0442, P0456 or P1450. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Follow the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostic procedures for any DTC code that may be present to ensure the Evaporative Emissions (EVAP) system is functioning properly. 2. When performing EVAP diagnostics on Escape Hybrid and Mariner Hybrid vehicles, the ambient temperature must be greater than 32 °F (0 °C) and the heating ventilation air conditioning (HVAC) system should be set to Defrost. This will provide continuous gasoline engine operation. 3. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 60.11 and higher or 61.01 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 100103A 2010 Fusion Hybrid/Milan 0.3 Hr. Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) 100103A 2009 Escape 0.3 Hr. Hybrid/Mariner Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 2732 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Engine Control Module: All Technical Service Bulletins Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2738 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0442/P0456/P1450 TSB 10-1-3 02/01/10 HYBRID ONLY - DTCS P0442, P0456 OR P1450 - BUILT ON OR BEFORE 4/6/2009 FORD: 2010 Fusion 2009 Escape MERCURY: 2010 Milan 2009 Mariner This article supersedes TSB 09-9-9 to add a production fix date. ISSUE Some 2009 Escape Hybrid, Mariner Hybrid, 2010 Fusion Hybrid and Milan Hybrid vehicles built on or before 4/6/2009 may exhibit a malfunction indicator light (MIL) accompanied by diagnostic trouble code (DTC) P0442, P0456 or P1450. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Follow the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostic procedures for any DTC code that may be present to ensure the Evaporative Emissions (EVAP) system is functioning properly. 2. When performing EVAP diagnostics on Escape Hybrid and Mariner Hybrid vehicles, the ambient temperature must be greater than 32 °F (0 °C) and the heating ventilation air conditioning (HVAC) system should be set to Defrost. This will provide continuous gasoline engine operation. 3. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 60.11 and higher or 61.01 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 100103A 2010 Fusion Hybrid/Milan 0.3 Hr. Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) 100103A 2009 Escape 0.3 Hr. Hybrid/Mariner Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 2743 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2744 Engine Control Module: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2745 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2746 Engine Control Module: Diagrams Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2747 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2748 Part 3 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2749 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2750 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2751 Part 3 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2752 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2753 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory (EEPROM) WARNING: THIS VEHICLE IS EQUIPPED WITH HIGH VOLTAGE CABLES, COMPONENTS, AND WIRING. THE HIGH VOLTAGE WARNING LABELS CONTAINING THE HIGH VOLTAGE SYMBOL ARE LOCATED ON EACH HIGH VOLTAGE COMPONENT. HIGH VOLTAGE CABLES AND WIRING ARE ORANGE IN COLOR. CERTIFIED RUBBER INSULATING GLOVES AND A FACE SHIELD MUST BE WORN WHEN WORKING WITH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING. THE IGNITION KEY MUST BE CYCLED TO THE OFF POSITION FOR A MINIMUM OF 5 MINUTES, AND THE HIGH VOLTAGE TRACTION BATTERY SERVICE DISCONNECT PLUG PLACED IN THE SERVICING/SHIPPING POSITION BEFORE DISCONNECTING THE HIGH VOLTAGE CABLES. DO NOT DISCONNECT, DISABLE, OR TOUCH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING DURING THE MODULE REPROGRAMMING PROCEDURE BECAUSE HIGH VOLTAGE IS PRESENT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH. Description Flash electrically erasable programmable read only memory (EEPROM) is contained in an integrated circuit internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block must be programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate diagnostic trouble code (DTC) P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. Failure to carry out this procedure correctly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, and the presence of speed control. Only items applicable to vehicle hardware and supported by the VID block are displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. On selected vehicles equipped with permanent DTC reporting capabilities, neutral profile correction should be learned after a PCM replacement in order to activate the misfire monitor. This can be accomplished using the Misfire Monitor Neutral Profile Learn function on the scan tool. Reprogramming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the manufacturer's user manual for details. Programming the VID Block for a Replacement PCM The VID block on a replacement PCM is blank and requires programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it is replaced. Manual data entry must be carried out if the old module is damaged and is incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the Module/Parameter programming, referring to the manufacturer's user manual. Make certain that all parameters are included. Failure to correctly program tire size in revolutions per mile, (rev/mile = 63,360 divided by the tire circumference in inches) or axle ratio, may result in codes P1635 and P1639. You may be instructed to contact the As Built data center for the information needed to manually update the VID block with the scan tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury technicians, contact the National Hotline or Professional Technician Society (PTS) website for As Built data. Non-Ford technicians, use the Motorcraft website at Motorcraft.com. From the Motorcraft homepage, use the search function to find the Module Programming or As Built Data. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the scan tool. PCM Reprogramming Note: After the PCM is successfully reprogrammed, clear any TCM DTCs that may have been stored during reprogramming. At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2756 Engine Control Module: Removal and Replacement Powertrain Control Module (PCM) Removal 1. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation (PMI) procedure. See: Information Bus/Testing and Inspection/Programming and Relearning 2. Detach the wiring harness retainer from the cowl stud bolt. 3. Disconnect the 3 PCM electrical connectors. 4. Remove the 2 bolts and the PCM. 5. Remove and inspect the PCM cowl seal. Install new if damaged. Installation 1. Install the PCM cowl seal. 2. Install the PCM and the 2 bolts. - Tighten to 8 Nm (71 lb-in). 3. Connect the 3 PCM electrical connectors. 4. Attach the wiring harness retainer to the cowl stud bolt. 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation (PMI) procedure. See: Information Bus/Testing and Inspection/Programming and Relearning Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2764 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2765 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the powertrain control module (PCM) receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Accelerator Pedal Position (APP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2769 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2770 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. 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 volume of air 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. The MAF sensor is located between the air cleaner and the throttle body inside the air cleaner assembly. Mass Air Flow (MAF) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2771 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 screws and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2775 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2776 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The CMP sensor is a Hall-effect sensor that detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. The PCM also uses the CMP signal to select the correct ignition coil to fire. Typical Hall-effect CMP Sensor Camshaft Position (CMP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2777 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 3. NOTE: Lubricate the CMP sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2781 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2782 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates the 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. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between pulse wheel teeth. Typical Crankshaft Position (CKP) Sensor Crankshaft Position (CKP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2783 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts, the pin-type retainer (not shown) and the RH splash shield. 3. Turn the crankshaft clockwise until the hole in the crankshaft pulley is in the 3 o'clock position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2784 4. Remove the engine plug bolt. 5. NOTE: When the crankshaft contacts the Crankshaft TDC Timing Peg, the No. 1 cylinder will be at Top Dead Center (TDC). Install the Crankshaft TDC Timing Peg and turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg. 6. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 7. Remove the bolts and the CKP sensor. Installation 1. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6 mm x 18 mm bolt in the crankshaft pulley and thread it into the front cover. 2. Install the CKP sensor and the 2 bolts. - Do not tighten the bolts at this time. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2785 3. Adjust the CKP sensor with the Crankshaft Sensor Aligner. - Tighten the 2 CKP bolts to 7 Nm (62 lb-in). 4. Connect the CKP sensor electrical connector. 5. Remove the 6 mm x 18 mm bolt from the crankshaft pulley. 6. Install the engine plug bolt. - Tighten to 20 Nm (177 lb-in). 7. Install the RH splash shield, 5 bolts and the pin-type retainer (not shown). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2789 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2790 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which the resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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 varying the resistance of the passive sensor causes a variation in total current flow. The CHT sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor provides 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 then initiates 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 See: Description and Operation/Powertrain Control Software Fail-Safe Cooling Strategy. Cylinder Head Temperature (CHT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2791 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. Detach the Cylinder Head Temperature (CHT) sensor cover and position aside. 2. Disconnect the CHT sensor electrical connector. 3. Remove the CHT sensor. - To install, tighten to 12 Nm (106 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Level Sensor: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Fuel Tank Filler Pipe Assembly Fuel Tank and Fuel Pump (FP) module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2796 Fuel Tank Supports Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2797 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2798 Fuel Level Sensor: Service and Repair Fuel Pump Module Fuel Pump Module Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the Fuel Pump (FP) module access cover. 4. NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material. Disconnect the FP module electrical connector. 5. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage. Disconnect the fuel tube-to-FP module quick connect coupling. 6. Disconnect the fuel tank filler pipe recirculation tube-to-FP module quick connect coupling. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2799 7. NOTE: For initial fuel draining, it is required to remove the fuel through the fuel tank filler pipe recirculation tube port on the FP module. Connect the Fuel Storage Tanker to the fuel tank filler pipe recirculation tube port on the FP module and remove approximately one-fourth of the fuel (from a completely full tank), lowering the fuel level below the FP module mounting flange. 8. NOTICE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP module when removing the lock ring. NOTE: When installing the FP module, install a new O-ring seal. Install the Fuel Tank Sender Unit Wrench and remove the FP module lock ring. 9. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm. NOTE: Some residual fuel may remain in the FP module. Carefully drain into a suitable container. Completely remove the FP module from the fuel tank. 10. NOTE: Inspect the surfaces of the FP module flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded. NOTE: To install, apply clean engine oil to the O-ring seal. Remove and discard the FP module O-ring seal. 11. NOTE: Make sure to install a new FP module O-ring seal and lock ring. To install, reverse the removal procedure. Make sure the alignment arrows on the FP module and the fuel tank meet before tightening the FP module lock ring. - Tighten the FP lock ring until it meets the stop tabs on the fuel tank. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2800 Fuel Level Sensor: Service and Repair Fuel Level Sender Fuel Level Sender Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the Fuel Pump (FP) module. For additional information, refer to Fuel Pump Module See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Pump Module. 2. Disconnect the electrical connector, release the locking tabs and remove the fuel level sender from the FP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2801 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 2805 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor The FTP sensor is used to measure the fuel tank pressure. In-line Fuel Tank Pressure (FTP) Sensor Fuel Tank Pressure (FTP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2809 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2810 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The IAT sensor is integrated into the mass air flow (MAF) sensor. It is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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. A thermistor type sensor is considered a passive sensor. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in the 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 sensor provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, and ignition timing. Integrated Intake Air Temperature (IAT) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2814 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2815 Knock Sensor: Description and Operation Knock Sensor (KS) The KS 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2816 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the intake manifold. 3. Remove the bolt and the Knock Sensor (KS). - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2820 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2821 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor uses a piezo-resistive silicon sensing element to provide a voltage proportional to the absolute pressure in the intake manifold. The MAP sensor is part of the EGR system. The PCM uses information from the MAP, TP, MAF, CHT and CKP sensors to determine how much exhaust gas is introduced into the intake manifold. Typical Manifold Absolute Pressure (MAP) Sensor Manifold Absolute Pressure (MAP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2822 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure (MAP) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the Throttle Body (TB). 3. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector. 4. Using a tool like KD Tool #58181 or Lisle T25 Torx Bit, remove the screw and the MAP sensor. - To install, tighten to 3 Nm (27 lb-in). 5. NOTE: Lubricate the MAP sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Oxygen Sensor: Customer Interest Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2831 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Oxygen Sensor: All Technical Service Bulletins Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2837 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2840 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #12 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #12 > Page 2843 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2844 Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) The HO2S 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 voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a 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 a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Typical Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) Universal Heated Oxygen Sensor (HO2S) The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal HO2S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor Exploded View Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page 2847 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S. - Calculate the correct torque wrench setting for the following torque. - To install, tighten to 48 Nm (35 lb-ft). 4. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page 2848 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor Catalyst Monitor Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector. 3. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS. - Calculate the correct torque wrench setting for the following torque. - To install, tighten to 48 Nm (35 lb-ft). 4. NOTE: Apply a light coat of anti-seize lubricant to the threads of the CMS. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has two signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The two ETB throttle position sensor signals make sure the PCM receives a correct input even if one signal has a concern. There is one reference voltage circuit and one signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to the description of the Torque Based Electronic Throttle Control (ETC) See: Electronic Throttle Control Module/Description and Operation. Electronic Throttle Body (ETB) Throttle Position Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has two signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The two ETB throttle position sensor signals make sure the PCM receives a correct input even if one signal has a concern. There is one reference voltage circuit and one signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to the description of the Torque Based Electronic Throttle Control (ETC) See: Electronic Throttle Control Module/Description and Operation. Electronic Throttle Body (ETB) Throttle Position Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2858 Variable Valve Timing Actuator: Description and Operation Variable Camshaft Timing (VCT) System Overview The intake phase shifting (IPS) VCT system enables rotation of the intake camshaft relative to the crankshaft rotation as a function of engine operating conditions. The VCT system has several operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on a constant angle, limited by engine oil temperature and engine RPM. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. Variable Camshaft Timing (VCT) System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel indicates the CMP signal for that bank. A crankshaft position (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT), cylinder head temperature (CHT), CMP, accelerator pedal position (APP) sensor (via requested torque), mass air flow (MAF), and CKP sensors to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on engine oil temperature and engine speed inputs. During cold start emissions reduction mode, the camshaft position is determined via engine speed and estimates of engine coolant temperature and catalyst temperature (estimated from other sensors already used such as IAT/CHT/MAF/CKP). During part and wide open throttle, the camshaft position is determined by engine RPM, load and accelerator pedal position. The VCT system does not operate until the engine is at normal operating oil temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a default position if a concern is detected. A related diagnostic trouble code (DTC) is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the two halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. VCT System Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair Variable Valve Timing Solenoid: Service and Repair Variable Camshaft Timing (VCT) Oil Control Solenoid Removal and Installation 1. Remove the valve cover. 2. Remove the bolt and the Variable Camshaft Timing (VCT) oil control solenoid. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalytic Converter Mounting Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter Mounting Gasket: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Catalytic Converter Mounting Gasket: All Technical Service Bulletins Engine Controls/Exhaust MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalytic Converter Mounting Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter Mounting Gasket: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2872 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalytic Converter Mounting Gasket > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter Mounting Gasket: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Catalytic Converter Mounting Gasket: Customer Interest Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalytic Converter Mounting Gasket > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter Mounting Gasket: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 2878 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Control Valve: > 11-1-5 > Jan > 11 > Emissions - Rough Running/Hard Start/DTC's Set Canister Purge Control Valve: Customer Interest Emissions - Rough Running/Hard Start/DTC's Set TSB 11-1-5 01/25/11 RUNS ROUGH, HARD START AFTER REFUELING, AUDIBLE CLICKING NOISE UNDER HOOD, AND/OR DTCS P0316, P144A, P1450, PO17X, P044X, P045X, BUILT ON OR BEFORE 11/1/2010 FORD: 2010-2011 Fusion 2009-2010 F-150 2009-2011 E-Series, Escape, Expedition 2011 F-250, F-350 LINCOLN: 2011 MKZ 2009-2011 Navigator MERCURY: 2010-2011 Milan 2009-2011 Mariner ISSUE Some 2009-2010 F-150, 2009-2011 Expedition, Navigator, E-Series, Escape Hybrid, Mariner Hybrid, 2010-2011 Fusion Hybrid, Milan Hybrid, 2011 MKZ Hybrid and F-Super Duty 250/350 equipped with a 6.2L engine and built on or before 11/1/2010, may exhibit a running rough concern, hard start after refueling, audible clicking noise under the hood and/or diagnostic trouble codes (DTCs) P0316, P144A, P1450, PO17X, P044X, P045X. ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE Replace the Evaporative Emission Canister Purge Valve. Refer to Workshop Manual, Section 303-13. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Control Valve: > 11-1-5 > Jan > 11 > Emissions - Rough Running/Hard Start/DTC's Set > Page 2888 OPERATION DESCRIPTION TIME 110105A 2009-2011 Expedition, 0.6 Hr. Navigator, And Econoline 2009-2010 F-150: Check DTCs, And Replace The Evaporative Emission Canister Purge Valve (Do Not Use With Any Other Labor Operations) 110105A 2009-2011 Escape Hybrid, 0.7 Hr. Mariner Hybrid, 2010-2011 Fusion Hybrid, Milan Hybrid, 2011 MKZ Hybrid, And 2011 F-Super Duty 6.2L: Check DTCs, And Replace The Evaporative Emission Canister Purge Valve (Do Not Use With Any Other Labor Operations) 110105A 2009-2011 Econoline: 0.9 Hr. Check DTCs, And Replace The Evaporative Emission Canister Purge Valve (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 9C915 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Control Valve: > 11-1-5 > Jan > 11 > Emissions - Rough Running/Hard Start/DTC's Set Canister Purge Control Valve: All Technical Service Bulletins Emissions - Rough Running/Hard Start/DTC's Set TSB 11-1-5 01/25/11 RUNS ROUGH, HARD START AFTER REFUELING, AUDIBLE CLICKING NOISE UNDER HOOD, AND/OR DTCS P0316, P144A, P1450, PO17X, P044X, P045X, BUILT ON OR BEFORE 11/1/2010 FORD: 2010-2011 Fusion 2009-2010 F-150 2009-2011 E-Series, Escape, Expedition 2011 F-250, F-350 LINCOLN: 2011 MKZ 2009-2011 Navigator MERCURY: 2010-2011 Milan 2009-2011 Mariner ISSUE Some 2009-2010 F-150, 2009-2011 Expedition, Navigator, E-Series, Escape Hybrid, Mariner Hybrid, 2010-2011 Fusion Hybrid, Milan Hybrid, 2011 MKZ Hybrid and F-Super Duty 250/350 equipped with a 6.2L engine and built on or before 11/1/2010, may exhibit a running rough concern, hard start after refueling, audible clicking noise under the hood and/or diagnostic trouble codes (DTCs) P0316, P144A, P1450, PO17X, P044X, P045X. ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE Replace the Evaporative Emission Canister Purge Valve. Refer to Workshop Manual, Section 303-13. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Control Valve: > 11-1-5 > Jan > 11 > Emissions - Rough Running/Hard Start/DTC's Set > Page 2894 OPERATION DESCRIPTION TIME 110105A 2009-2011 Expedition, 0.6 Hr. Navigator, And Econoline 2009-2010 F-150: Check DTCs, And Replace The Evaporative Emission Canister Purge Valve (Do Not Use With Any Other Labor Operations) 110105A 2009-2011 Escape Hybrid, 0.7 Hr. Mariner Hybrid, 2010-2011 Fusion Hybrid, Milan Hybrid, 2011 MKZ Hybrid, And 2011 F-Super Duty 6.2L: Check DTCs, And Replace The Evaporative Emission Canister Purge Valve (Do Not Use With Any Other Labor Operations) 110105A 2009-2011 Econoline: 0.9 Hr. Check DTCs, And Replace The Evaporative Emission Canister Purge Valve (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 9C915 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Page 2895 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Page 2896 Canister Purge Control Valve: Description and Operation Evaporative Emission (EVAP) Canister Purge Valve The EVAP canister purge valve is part of the enhanced EVAP system that is controlled by the PCM. This valve controls the flow of vapors (purging) from the EVAP canister to the intake manifold during various engine operating modes. The EVAP canister purge valve is a normally closed valve. The EVAP canister purge valve controls the flow of vapors electronically by way of a solenoid, eliminating the need for an electronic vacuum regulator and vacuum diaphragm. The PCM outputs a duty cycle between 0% and 100% to control the EVAP canister purge valve. EVAP Canister Purge Valve Typical EVAP Canister Purge Valve (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Page 2897 Canister Purge Control Valve: Service and Repair Evaporative Emission Canister Purge Valve Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Disconnect the battery ground cable. 2. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector. 3. Disconnect the fuel vapor tube-to-EVAP canister purge valve quick connect coupling. 4. Remove the 2 bolts and the EVAP canister purge valve. - To install, tighten to 6 Nm (53 lb-in). 5. To install, reverse the removal procedure. - Carry out the Evaporative Emission System Leak Test. For additional information, refer to Evaporative Emission System Leak Test See: Testing and Inspection. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Diagrams > Page 2901 Evaporative Check Valve: Description and Operation Fuel Vapor Vent Valve The fuel vapor vent valve is a PCM-controlled solenoid that isolates the fuel tank from the rest of the EVAP system. The fuel vapor vent valve is a normally open valve allowing the flow of vapors from the fuel tank to the electronic EVAP canister purge valve and the EVAP canister. The PCM controls the fuel vapor vent valve on/off cycle whenever it is desired to isolate the fuel tank from the rest of the EVAP system. Fuel Vapor Vent Valve Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair Canister Vent Valve: Service and Repair Fuel Vapor Vent Valve Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the Evaporative Emission (EVAP) canister assembly. For additional information, refer to Evaporative Emission Canister See: Service and Repair. 2. Disconnect the fuel vapor vent-to-EVAP canister quick connect coupling. 3. Disconnect the fuel vapor vent valve electrical connector. 4. Remove the fuel vapor vent valve from the EVAP canister tray. 5. To install, reverse the removal procedure. - Carry out the Evaporative Emission System Leak Test. For additional information, refer to Evaporative Emission System Leak Test See: Testing and Inspection. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair Evaporative Emissions Hose: Service and Repair Fuel Vapor Tube Assembly Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Position the Powertrain Lift under the fuel tank. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Page 2909 4. Remove the LH fuel tank strap bolt and position the strap aside. - To install, tighten to 55 Nm (41 lb-ft). 5. Partially lower the LH side of the fuel tank enough to access the fuel vapor tube assembly. 6. Disconnect the Fuel Tank Pressure (FTP) sensor electrical connector. 7. Disconnect the fuel vapor tube assembly-to-fuel tank quick connect coupling. 8. Disconnect the fuel vapor tube assembly-to-fuel vapor vent valve quick connect coupling. 9. Remove the fuel vapor tube assembly. 10. To install, reverse the removal procedure. - Carry out the Evaporative Emission System Leak Test. For additional information, refer to Evaporative Emission System Leak Test See: Testing and Inspection. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 2913 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 2914 Leak Detection Valve: Description and Operation Canister Vent (CV) Solenoid During the evaporative emissions (EVAP) leak check monitor, the CV solenoid seals the EVAP canister from the atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel tank during the EVAP leak check monitor. Typical Canister Vent (CV) Solenoid Canister Vent (CV) Solenoid Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 2915 Leak Detection Valve: Service and Repair Evaporative Emission Canister Vent Solenoid Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 2916 1. Remove the Evaporative Emission (EVAP) canister assembly. For additional information, refer to Evaporative Emission Canister See: Evaporative Emission Control Canister/Service and Repair. 2. Disconnect the EVAP canister vent solenoid and fuel vapor vent valve electrical connectors, release the pin-type retainer and remove the EVAP canister wire harness. 3. Remove the 3 EVAP canister tray bolts. - To install, tighten to 5 Nm (44 lb-in). 4. Disconnect the EVAP canister purge tube-to-EVAP canister quick connect coupling. 5. Disconnect the fuel vapor vent valve-to-EVAP canister quick connect coupling. 6. Remove the EVAP canister from the tray. 7. Depress the locking tab outward, rotate the EVAP canister vent solenoid clockwise and remove it from the EVAP canister. - Apply clean engine oil to the EVAP canister vent solenoid O-ring seal prior to installation. 8. To install, reverse the removal procedure. - Carry out Evaporative Emission System Leak Test. For additional information, refer to Evaporative Emission System Leak Test See: Testing and Inspection. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 2921 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 2922 EGR Valve: Description and Operation Electric Exhaust Recirculation Valve (EEGR) Valve The EEGR valve is a water-cooled motor/valve assembly. The motor is commanded to move in 52 discrete steps as it acts directly on the EEGR valve. The position of the valve determines the rate of EGR. The built-in spring works to close the valve against the motor opening force. EEGR Motor/Valve Assembly Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 2923 EGR Valve: Service and Repair Exhaust Gas Recirculation (EGR) Valve Coolant Outlet EGR Valve Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 2924 Removal and Installation 1. Drain the cooling system. 2. Remove the Air Cleaner (ACL) outlet pipe. 3. Release the clamp and remove the upper radiator hose from the coolant outlet. 4. Release the clamp and remove the coolant bypass hose from the coolant outlet. 5. Release the clamp and remove the heater hose from the coolant outlet. 6. Remove the 4 bolts and the coolant outlet and gasket. - To install, tighten to 10 Nm (89 lb-in). 7. Disconnect the EGR valve electrical connector. 8. Release the clamp and remove the coolant hose from the EGR valve. 9. Remove the 2 bolts and the EGR valve. - To install, tighten to 20 Nm (177 lb-in). 10. NOTICE: 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 that make leak paths. Use a plastic scraping tool to remove all traces of the exhaust gas recirculation (EGR) valve gasket. NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces NOTE: Do not reuse the EGR valve gasket. Remove and discard the EGR valve gasket. Clean and inspect the EGR gasket mating surfaces. 11. NOTE: Install a new EGR valve and coolant outlet gaskets. To install, reverse the removal procedure. 12. Fill and bleed the cooling system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Oil Separator > Component Information > Service and Repair Oil Separator: Service and Repair Crankcase Vent Oil Separator Removal and Installation 1. Remove the intake manifold. 2. Release the coolant bypass hose from the clip. 3. Remove the 8 bolts, the crankcase vent oil separator and gasket. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. - Clean and inspect the crankcase oil vent separator gasket and replace if necessary. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure Key ON Engine OFF (KOEO)............................................................................................................... .........................................................379 kPa (55 psi) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2933 Fuel Pressure: Testing and Inspection Fuel System Pressure Test WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. NOTE: Early build 3.0L engines are equipped with a Schrader valve on the fuel rail. Late build 3.0L engines do not have a Schrader valve. All vehicles 1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. For additional information, refer to Battery. Vehicles with 2.5L engine 3. Disconnect the fuel tube-to-fuel rail quick connect coupling. For additional information, refer to Quick Connect Coupling See: Fuel Line Coupler/Service and Repair/Quick Connect Coupling. 4. Install the Fuel Pressure Test Kit between the fuel tube and the fuel rail. Vehicles with early build 3.0L engine 5. Remove the fuel rail Schrader valve cap. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2934 6. Install the Fuel Pressure Test Kit to the fuel rail Schrader valve. Vehicles with late build 3.0L engine 7. Disconnect the fuel jumper tube-to-fuel tube quick connect coupling. For additional information, refer to Quick Connect Coupling See: Fuel Line Coupler/Service and Repair/Quick Connect Coupling. 8. Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel tube. All vehicles 9. NOTE: The Fuel Pump (FP) fuse was removed previously to release the fuel system pressure and must be installed to test the fuel system pressure. Install the FP fuse. 10. Connect the battery ground cable. For additional information, refer to Battery. 11. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 12. NOTE: Upon completion of the fuel system pressure test, open the drain valve on the Fuel Pressure Test Kit and release fuel system pressure and drain any residual fuel into a suitable container prior to removing the tool. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel System Pressure Release WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. NOTE: The Fuel Pump (FP) fuse is located in the Battery Junction Box (BJB), location 22. Remove the FP fuse. 2. Start the engine and allow it to idle until it stalls. 3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released. 4. Turn the ignition switch to the OFF position. 5. When the fuel system service is complete, install the FP fuse. 6. NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for leaks prior to starting the engine. Start the vehicle and check the fuel system for leaks. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Measured/PID Values Hot Idle ................................................................................................................................................ ............................................................. 1072 RPM Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair Accelerator Pedal: Service and Repair Accelerator Pedal 2.5L and 3.0L Vehicles 2.5L Hybrid Vehicles Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Page 2944 Removal and Installation All vehicles NOTE: The accelerator pedal and sensor assembly on the 2.5L and 3.0L are similar in appearance to the 2.5L Hybrid but are not interchangeable. 1. Disconnect the battery ground cable. 2.5L and 3.0L vehicles 2. Remove the 3 self-tapping screws and the accelerator pedal and sensor assembly. - To install, tighten to 7 Nm (62 lb-in). 2.5L Hybrid vehicles 3. Remove the 3 bolts and the accelerator pedal and sensor assembly. - To install, tighten to 10 Nm (89 lb-in). All vehicles 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2948 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2949 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the powertrain control module (PCM) receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Accelerator Pedal Position (APP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Intake Air System Components - Exploded View Air Cleaner (ACL) Assembly and Outlet Pipe Air Cleaner (ACL) Intake Pipe Intake Air Resonator Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2954 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2958 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2959 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. 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 volume of air 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. The MAF sensor is located between the air cleaner and the throttle body inside the air cleaner assembly. Mass Air Flow (MAF) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2960 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 screws and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel System Pressure Release WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. NOTE: The Fuel Pump (FP) fuse is located in the Battery Junction Box (BJB), location 22. Remove the FP fuse. 2. Start the engine and allow it to idle until it stalls. 3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released. 4. Turn the ignition switch to the OFF position. 5. When the fuel system service is complete, install the FP fuse. 6. NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for leaks prior to starting the engine. Start the vehicle and check the fuel system for leaks. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings Fuel Line Coupler: Service and Repair Spring Lock Couplings Spring Lock Couplings Disconnect WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. NOTICE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearance. It is essential that absolute cleanliness is observed when working with these components or component damage can occur. Always install plugs to any open orifices or tubes. 1. If servicing a liquid fuel tube spring lock coupling, release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. 3. Remove the safety clip from the spring lock coupling. 4. Insert the Spring Lock Coupling Disconnect Tool onto the fuel tube and into the spring lock coupling. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 2973 5. Separate the spring lock coupling from the fuel tube. Connect 1. Clean and inspect the fuel tube and spring lock coupling. - Lubricate the end of the fuel tube with clean engine oil. 2. Install the spring lock coupling onto the fuel tube until fully seated. 3. Pull on the spring lock coupling to make sure it is correctly locked onto the fuel tube. 4. Install the safety clip onto the spring lock coupling. 5. Connect the battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 2974 Fuel Line Coupler: Service and Repair Quick Connect Coupling Quick Connect Coupling Disconnect - Type I WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. NOTICE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearance. It is essential that absolute cleanliness is observed when working with these components or component damage can occur. Always install plugs to any open orifices or tubes. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. 3. NOTE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. Disconnect the quick connect coupling from the tube. - Press the quick connect coupling release button and separate the quick connect coupling from the tube. Connect - Type I 1. NOTE: Apply clean engine oil to the end of the tube and the quick connect coupling O-ring seals. NOTE: Make sure the tube clicks into place when installing into the quick connect coupling. To make sure that the tube is fully seated, pull on the tube. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 2975 Install the quick connect coupling onto the tube until fully seated. 2. Connect the battery ground cable. Disconnect - Type II WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. NOTICE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearance. It is essential that absolute cleanliness is observed when working with these components or component damage can occur. Always install plugs to any open orifices or tubes. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. Disconnect the battery ground cable. 2. Rotate the lock tab on the quick connect coupling. 3. NOTE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. Disconnect the quick connect coupling from the fitting. - Pull on the quick connect coupling and separate from the fitting. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 2976 Connect - Type II 1. NOTE: Apply clean engine oil to the end of the tube and the quick connect coupling O-ring seals. Rotate the lock tab and install the quick connect coupling onto the fitting. 2. NOTE: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. Release the lock tab into the latched position. 3. Connect the battery ground cable. Disconnect - Type III WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. NOTICE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearance. It is essential that absolute cleanliness is observed when working with these components or component damage can occur. Always install plugs to any open orifices or tubes. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 2977 2. Disconnect the battery ground cable. 3. NOTE: Carefully release the lock tab to avoid breakage. Release the quick connect coupling primary lock tab. 4. Rotate the primary lock tab to the fully unlocked position and squeeze the secondary lock tabs to release the locking mechanism. 5. NOTE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. Disconnect the quick connect coupling from the tube. - Push the locking mechanism outward and separate the quick connect coupling from the tube. Connect - Type III 1. NOTE: Apply clean engine oil to the end of the tube and the quick connect coupling O-ring seals. NOTE: Make sure the tube clicks into place when installing it into the quick connect coupling. To make sure the tube is fully seated, pull on the tube. Install the quick connect coupling onto the tube until fully seated. 2. NOTE: Make sure the retainer clip clicks into place when installing. Depress the retainer clip until it is flush with the quick connect coupling housing. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 2978 3. NOTE: To make sure the tube is fully seated, pull on the quick connect coupling. Rotate the primary locking tab to the closed position. 4. Connect the battery ground cable. Disconnect - Type IV WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. NOTICE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearance. It is essential that absolute cleanliness is observed when working with these components or component damage can occur. Always install plugs to any open orifices or tubes. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. 3. Squeeze the quick connect coupling retainer clip tabs to release the locking mechanism. 4. NOTE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. Disconnect the quick connect coupling from the tube. - Push the locking mechanism outward to release the quick connect coupling. - Pull on the quick connect coupling and separate it from the tube. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 2979 Connect - Type IV 1. NOTE: Apply clean engine oil to the end of the tube and the quick connect coupling O-ring seals. NOTE: Make sure the tube clicks into place when installing into the quick connect coupling. To make sure that the tube is fully seated, pull on the tube. Connect the quick connect coupling to the tube. 1. Install the quick connect coupling onto the tube until it is fully seated. 2. Depress the locking tab until it is flush with the quick connect coupling housing. 2. Connect the battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure Key ON Engine OFF (KOEO)............................................................................................................... .........................................................379 kPa (55 psi) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2987 Fuel Pressure: Testing and Inspection Fuel System Pressure Test WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. NOTE: Early build 3.0L engines are equipped with a Schrader valve on the fuel rail. Late build 3.0L engines do not have a Schrader valve. All vehicles 1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. For additional information, refer to Battery. Vehicles with 2.5L engine 3. Disconnect the fuel tube-to-fuel rail quick connect coupling. For additional information, refer to Quick Connect Coupling See: Fuel Line Coupler/Service and Repair/Quick Connect Coupling. 4. Install the Fuel Pressure Test Kit between the fuel tube and the fuel rail. Vehicles with early build 3.0L engine 5. Remove the fuel rail Schrader valve cap. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2988 6. Install the Fuel Pressure Test Kit to the fuel rail Schrader valve. Vehicles with late build 3.0L engine 7. Disconnect the fuel jumper tube-to-fuel tube quick connect coupling. For additional information, refer to Quick Connect Coupling See: Fuel Line Coupler/Service and Repair/Quick Connect Coupling. 8. Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel tube. All vehicles 9. NOTE: The Fuel Pump (FP) fuse was removed previously to release the fuel system pressure and must be installed to test the fuel system pressure. Install the FP fuse. 10. Connect the battery ground cable. For additional information, refer to Battery. 11. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 12. NOTE: Upon completion of the fuel system pressure test, open the drain valve on the Fuel Pressure Test Kit and release fuel system pressure and drain any residual fuel into a suitable container prior to removing the tool. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations > Page 2992 Fuel Pump Control Unit: Service and Repair Fuel Pump Control Module Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Fuel Pump (FP) control module electrical connector. 3. NOTICE: Do not overtighten the fasteners or damage will occur. Remove the 2 bolts and the FP control module. - To install, tighten to 5 Nm (44 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Fuel Rail: Service and Repair Fuel Rail Fuel Rail Removal WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel supply tube-to-fuel quick connect coupling. 4. Disconnect the 4 fuel injector electrical connectors. 5. Remove the nut and position the radio capacitor aside. 6. Detach the 2 pin-type wire harness retainers from the fuel rail. 7. Remove the 2 fuel rail stud bolts. 8. Remove the fuel rail and injectors as an assembly. 9. Remove the 4 fuel injector retainer clips and the 4 fuel injectors. - Remove and discard the 8 fuel injector O-ring seals. Installation 1. NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals. NOTE: Install 8 new fuel injector O-ring seals and lubricate them with clean engine oil. Install the 4 fuel injectors and the 4 retainer clips on the fuel rail. 2. Install the fuel rail and injectors as an assembly. 3. Install the 2 fuel rail stud bolts. - Tighten to 23 Nm (17 lb-ft). 4. Attach the 2 pin-type wire harness retainers to the fuel rail. 5. Position the radio capacitor and install the nut. - Tighten to 10 Nm (89 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail > Page 2997 6. Connect the 4 fuel injector electrical connectors. 7. Connect the fuel supply tube-to-fuel rail quick connect coupling. 8. Connect the battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail > Page 2998 Fuel Rail: Service and Repair Fuel Rail and Fuel Injector - Exploded View Fuel Rail and Fuel Injector - Exploded View Fuel Rail Fuel Injector Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail > Page 2999 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Supply Line: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Fuel Tank Filler Pipe Assembly Fuel Tank and Fuel Pump (FP) module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3004 Fuel Tank Supports Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3005 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3006 Fuel Supply Line: Service and Repair Fuel Lines Fuel Lines Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. All vehicles 1. With vehicle in NEUTRAL, position it on a hoist. 2. Release the fuel system pressure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3007 3. Disconnect the battery ground cable. Hybrid vehicles 4. Remove the front and rear auxiliary evaporator outlet and inlet lines. All vehicles 5. NOTE: Some residual fuel may remain in the fuel tubes after releasing the fuel system pressure. Upon disconnecting or removing any fuel tubes, carefully drain any residual fuel into a suitable container. Disconnect the fuel supply jumper tube-to-fuel supply tube quick connect coupling. 6. Disconnect the fuel vapor tube-to-vapor tube quick connect coupling. 7. Remove the Fuel Pump (FP) module access cover. 8. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage. Disconnect the fuel tube-to-FP module quick connect coupling. 9. Disconnect the Evaporative Emission (EVAP) canister purge tube-to-vapor tube quick connect coupling (part of 9E857). 10. Release the 7 fuel tube bundle retainer clips and remove the fuel supply and vapor tubes. 11. Disconnect the fresh air tube from the EVAP canister. 12. Release the 4 pin-type retainer clips and remove the fresh air tube. 13. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Filler Hose: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Fuel Tank Filler Pipe Assembly Fuel Tank and Fuel Pump (FP) module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3013 Fuel Tank Supports Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3014 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3015 Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Fuel Tank Filler Pipe Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the Fuel Pump (FP) module access cover. 4. Disconnect the fuel tank filler pipe recirculation tube-to-FP module quick connect coupling. 5. Remove the 2 fuel tank filler pipe flange screws. - To install, tighten to 3 Nm (27 lb-in). 6. Remove the LR wheel and tire. 7. Remove the fuel tank filler pipe bracket bolt. - To install, tighten to 10 Nm (89 lb-in). 8. NOTE: Some residual fuel may remain in the fuel tank filler pipe. Carefully drain into a suitable container. Release the clamp and remove the fuel tank filler pipe hose from the fuel tank. - To install, tighten to 4 Nm (35 lb-in). 9. Remove the fuel tank filler pipe assembly. 10. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3019 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Gauge Sender: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Fuel Tank Filler Pipe Assembly Fuel Tank and Fuel Pump (FP) module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3022 Fuel Tank Supports Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3023 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3024 Fuel Gauge Sender: Service and Repair Fuel Pump Module Fuel Pump Module Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the Fuel Pump (FP) module access cover. 4. NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material. Disconnect the FP module electrical connector. 5. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage. Disconnect the fuel tube-to-FP module quick connect coupling. 6. Disconnect the fuel tank filler pipe recirculation tube-to-FP module quick connect coupling. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3025 7. NOTE: For initial fuel draining, it is required to remove the fuel through the fuel tank filler pipe recirculation tube port on the FP module. Connect the Fuel Storage Tanker to the fuel tank filler pipe recirculation tube port on the FP module and remove approximately one-fourth of the fuel (from a completely full tank), lowering the fuel level below the FP module mounting flange. 8. NOTICE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP module when removing the lock ring. NOTE: When installing the FP module, install a new O-ring seal. Install the Fuel Tank Sender Unit Wrench and remove the FP module lock ring. 9. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm. NOTE: Some residual fuel may remain in the FP module. Carefully drain into a suitable container. Completely remove the FP module from the fuel tank. 10. NOTE: Inspect the surfaces of the FP module flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded. NOTE: To install, apply clean engine oil to the O-ring seal. Remove and discard the FP module O-ring seal. 11. NOTE: Make sure to install a new FP module O-ring seal and lock ring. To install, reverse the removal procedure. Make sure the alignment arrows on the FP module and the fuel tank meet before tightening the FP module lock ring. - Tighten the FP lock ring until it meets the stop tabs on the fuel tank. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Fuel Tank Unit Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Fuel Tank Unit > Page 3031 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 3032 Fuel Tank Unit: Description and Operation Fuel Pump (FP) Module The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Fuel Pump (FP) Module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3036 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3037 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shut-off (IFS) Switch The IFS switch consists of a steel cone held in place by a magnet. When a sharp impact occurs, the cone breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner's Literature, Roadside Emergencies for the location of the IFS switch. Typical Inertia Fuel Shut-off (IFS) Switch Typical Inertia Fuel Shut-off (IFS) Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3038 Inertia Fuel Shutoff Switch: Service and Repair Inertia Fuel Shutoff (IFS) Switch 1. Remove the RH lower A-pillar trim panel. 2. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 3. Remove the 2 bolts and the IFS switch. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Intake Air System Components - Exploded View Intake Air Duct: Service and Repair Intake Air System Components - Exploded View Intake Air System Components - Exploded View Air Cleaner (ACL) Assembly and Outlet Pipe Air Cleaner (ACL) Intake Pipe Intake Air Resonator Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 3043 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 3044 Intake Air Duct: Service and Repair Air Cleaner Intake Pipe Air Cleaner Intake Pipe Removal and Installation 1. Remove the battery tray. 2. Remove the bolt and the Air Cleaner (ACL) intake pipe. - To install, tighten to 8 Nm (71 lb-in). 3. NOTE: Make sure that the front sponge seal of the intake pipe is seated on the shroud panel. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 3045 Intake Air Duct: Service and Repair Air Cleaner Outlet Pipe Air Cleaner Outlet Pipe Removal and Installation NOTICE: Do not disconnect the Air Cleaner (ACL) outlet pipe from the ACL cover. This is to protect the integrity of the hydrocarbon trap. 1. Disconnect the crankcase vent tube from the ACL outlet pipe. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Release the 2 ACL cover clamps. 4. Loosen the ACL outlet pipe-to-Throttle Body (TB) clamp and remove the ACL outlet pipe and ACL cover assembly. - To install, tighten to 4 Nm (35 lb-in). 5. NOTE: The ACL outlet pipe should be securely sealed to prevent unmetered air from entering the engine. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 3053 Fuel Pump Control Unit: Service and Repair Fuel Pump Control Module Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Fuel Pump (FP) control module electrical connector. 3. NOTICE: Do not overtighten the fasteners or damage will occur. Remove the 2 bolts and the FP control module. - To install, tighten to 5 Nm (44 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Resonator, Intake Air > Component Information > Service and Repair Resonator: Service and Repair Intake Air Resonator Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the LF wheel and tire. 3. Remove the 9 fasteners and position aside the LH fender splash shield. 4. Remove the bolt and the air intake resonator. - To install, tighten to 8 Nm (71 lb-in). 5. NOTE: Make sure that the front rubber grommet is seated in the bracket. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3064 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3065 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position (APP) Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the powertrain control module (PCM) receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Accelerator Pedal Position (APP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3069 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3070 Air Flow Meter/Sensor: Description and Operation Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. 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 volume of air 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. The MAF sensor is located between the air cleaner and the throttle body inside the air cleaner assembly. Mass Air Flow (MAF) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3071 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 screws and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 3078 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 3079 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shut-off (IFS) Switch The IFS switch consists of a steel cone held in place by a magnet. When a sharp impact occurs, the cone breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner's Literature, Roadside Emergencies for the location of the IFS switch. Typical Inertia Fuel Shut-off (IFS) Switch Typical Inertia Fuel Shut-off (IFS) Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 3080 Inertia Fuel Shutoff Switch: Service and Repair Inertia Fuel Shutoff (IFS) Switch 1. Remove the RH lower A-pillar trim panel. 2. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 3. Remove the 2 bolts and the IFS switch. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has two signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The two ETB throttle position sensor signals make sure the PCM receives a correct input even if one signal has a concern. There is one reference voltage circuit and one signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to the description of the Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. Electronic Throttle Body (ETB) Throttle Position Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 09-23-5 > Nov > 09 > Engine Controls - MIL ON/DTC P2135/P2111/P0122 Throttle Body: Customer Interest Engine Controls - MIL ON/DTC P2135/P2111/P0122 TSB 09-23-5 11/30/09 MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) P2135 - BUILT BETWEEN 6/22/2009-10/15/2009 FORD: 2010 Fusion 2009-2010 Escape MERCURY: 2010 Milan 2009-2010 Mariner ISSUE Some 2009-2010 Escape, Mariner, Escape Hybrid, Mariner Hybrid, 2010 Fusion, Milan, Fusion Hybrid, and Milan Hybrid vehicles, built on or between 6/22/2009 - 10/15/2009, may exhibit a malfunction indicator lamp (MIL) or wrench light with diagnostic trouble code (DTC) P2135. DTCs P2111 and/or P0122 may also be present. Drivability symptoms may include intermittent rough idle, idle speed below specification and/or reduced power. This concern may be attributed to Electronic Throttle Body (ETB) hardware. If the vehicle only exhibits DTCs P2111 or P0122 follow normal Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test (PPT) diagnostics. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check for DTCs and confirm vehicle build date. Is DTC P2135 present and vehicle built on or between 6/22/2009-10/15/2009? a. Yes - proceed to Step 2. b. No - Procedure does not apply. Refer to PC/ED PPT DV for appropriate diagnostic routines. 2. Replace the ETB per the Workshop Manual (WSM), Section 303-04. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 092305A 2009-2010 Escape, 0.6 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Replace The ETB, Includes Time To Check And Clear Codes (Do Not Use With Any Other Operations) 092305A 2010 Fusion, Fusion 0.6 Hr. Hybrid, Milan, Milan Hybrid 2.5L Engine: Replace The ETB, Includes Time To Check And Clear Codes (Do Not Use With Any Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 09-23-5 > Nov > 09 > Engine Controls - MIL ON/DTC P2135/P2111/P0122 > Page 3092 Other Operations) 092305A 2010 Fusion, Milan 3.0L 0.8 Hr. Engine: Replace The ETB Includes Time To Check And Clear Codes (Do Not Use With Any Other Operations) DEALER CODING CONDITION BASIC PART NO. CODE 9E926 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 09-8-9 > May > 09 > Fuel System - Red Triangle Displayed/DTC P1A0C Throttle Body: Customer Interest Fuel System - Red Triangle Displayed/DTC P1A0C TSB 09-8-9 05/04/09 RED TRIANGLE ON AND STOP SAFELY NOW MESSAGE - DTC P1A0C FORD: 2005-2009 Escape Hybrid MERCURY: 2006-2009 Mariner Hybrid ISSUE Some 2005-2009 Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit an intermittent Red Triangle On and Stop Safely Now message displayed on the message center accompanied by a sudden RPM loss/no start symptom with a diagnostic trouble code (DTC) P1A0C. Vehicles may exhibit this symptom on the first start of the morning or after an extended idle. The symptom will clear on the next key cycle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE For vehicles outside the new vehicle limited warranty, if diagnostics lead to replacing the throttle body you may use this procedure to clean the throttle body as an alternative to replacing it. This procedure is not covered by the new vehicle limited warranty. NOTE THIS CLEANING PROCEDURE CAN ONLY BE USED ON NON-COATED THROTTLE BODIES. Refer to Workshop Manual, Section 303-04C Removal and Installation - Throttle Body. 1. Remove the throttle body. 2. With the throttle body positioned to the side, open the throttle plate. 3. Using Motorcraft(R) Choke and Linkage Cleaner or equivalent, spray the throttle body plate and bore. 4. Using a suitable (nylon) brush, clean the edges of the throttle plate and the mating surface of the throttle bore to remove all carbon build up. 5. Reapply Motorcraft® Choke and Linkage Cleaner or equivalent and wipe clean with a lint-free cloth. 6. Remove old throttle body gasket and discard. Install a new throttle body gasket. 7. Install the throttle body. Parts Block WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-23-5 > Nov > 09 > Engine Controls - MIL ON/DTC P2135/P2111/P0122 Throttle Body: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2135/P2111/P0122 TSB 09-23-5 11/30/09 MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) P2135 - BUILT BETWEEN 6/22/2009-10/15/2009 FORD: 2010 Fusion 2009-2010 Escape MERCURY: 2010 Milan 2009-2010 Mariner ISSUE Some 2009-2010 Escape, Mariner, Escape Hybrid, Mariner Hybrid, 2010 Fusion, Milan, Fusion Hybrid, and Milan Hybrid vehicles, built on or between 6/22/2009 - 10/15/2009, may exhibit a malfunction indicator lamp (MIL) or wrench light with diagnostic trouble code (DTC) P2135. DTCs P2111 and/or P0122 may also be present. Drivability symptoms may include intermittent rough idle, idle speed below specification and/or reduced power. This concern may be attributed to Electronic Throttle Body (ETB) hardware. If the vehicle only exhibits DTCs P2111 or P0122 follow normal Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test (PPT) diagnostics. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check for DTCs and confirm vehicle build date. Is DTC P2135 present and vehicle built on or between 6/22/2009-10/15/2009? a. Yes - proceed to Step 2. b. No - Procedure does not apply. Refer to PC/ED PPT DV for appropriate diagnostic routines. 2. Replace the ETB per the Workshop Manual (WSM), Section 303-04. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 092305A 2009-2010 Escape, 0.6 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Replace The ETB, Includes Time To Check And Clear Codes (Do Not Use With Any Other Operations) 092305A 2010 Fusion, Fusion 0.6 Hr. Hybrid, Milan, Milan Hybrid 2.5L Engine: Replace The ETB, Includes Time To Check And Clear Codes (Do Not Use With Any Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-23-5 > Nov > 09 > Engine Controls - MIL ON/DTC P2135/P2111/P0122 > Page 3102 Other Operations) 092305A 2010 Fusion, Milan 3.0L 0.8 Hr. Engine: Replace The ETB Includes Time To Check And Clear Codes (Do Not Use With Any Other Operations) DEALER CODING CONDITION BASIC PART NO. CODE 9E926 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-8-9 > May > 09 > Fuel System - Red Triangle Displayed/DTC P1A0C Throttle Body: All Technical Service Bulletins Fuel System - Red Triangle Displayed/DTC P1A0C TSB 09-8-9 05/04/09 RED TRIANGLE ON AND STOP SAFELY NOW MESSAGE - DTC P1A0C FORD: 2005-2009 Escape Hybrid MERCURY: 2006-2009 Mariner Hybrid ISSUE Some 2005-2009 Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit an intermittent Red Triangle On and Stop Safely Now message displayed on the message center accompanied by a sudden RPM loss/no start symptom with a diagnostic trouble code (DTC) P1A0C. Vehicles may exhibit this symptom on the first start of the morning or after an extended idle. The symptom will clear on the next key cycle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE For vehicles outside the new vehicle limited warranty, if diagnostics lead to replacing the throttle body you may use this procedure to clean the throttle body as an alternative to replacing it. This procedure is not covered by the new vehicle limited warranty. NOTE THIS CLEANING PROCEDURE CAN ONLY BE USED ON NON-COATED THROTTLE BODIES. Refer to Workshop Manual, Section 303-04C Removal and Installation - Throttle Body. 1. Remove the throttle body. 2. With the throttle body positioned to the side, open the throttle plate. 3. Using Motorcraft(R) Choke and Linkage Cleaner or equivalent, spray the throttle body plate and bore. 4. Using a suitable (nylon) brush, clean the edges of the throttle plate and the mating surface of the throttle bore to remove all carbon build up. 5. Reapply Motorcraft® Choke and Linkage Cleaner or equivalent and wipe clean with a lint-free cloth. 6. Remove old throttle body gasket and discard. Install a new throttle body gasket. 7. Install the throttle body. Parts Block WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 08-23-12 > Nov > 08 > Temperature Display - Toggles From Fahrenheit To Celsius Instrument Panel Control Module: All Technical Service Bulletins Temperature Display - Toggles From Fahrenheit To Celsius TSB 08-23-12 11/24/08 FRONT DISPLAY INTERFACE MODULE (FDIM) - OUTSIDE TEMPERATURE DISPLAY TOGGLES BETWEEN FAHRENHEIT/CELSIUS FORD: 2008-2009 Escape Hybrid, Escape MERCURY: 2008-2009 Mariner Hybrid, Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles may exhibit an outside temperature display in the FDIM that toggles between Fahrenheit and Celsius. ACTION Reprogram the Instrument Cluster module to the latest calibration using IDS release 57.9 and higher with patch 13 or 58.2 and higher. This new calibration is not included in the VCM 2008.11 DVD. Calibration and IDS patch files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 082312A 2008-2009 Escape, 0.3 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Reprogram The Instrument Cluster, Authorization Decal Not Required.(Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 3117 Throttle Body: Service and Repair Throttle Body Removal and Installation 1. Remove the Air Cleaner (ACL) outlet pipe. 2. Disconnect the electronic throttle control electrical connector. 3. Remove the 4 bolts and the Throttle Body (TB). - Discard the TB gasket. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. - Install a new TB gasket. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has two signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The two ETB throttle position sensor signals make sure the PCM receives a correct input even if one signal has a concern. There is one reference voltage circuit and one signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to the description of the Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. Electronic Throttle Body (ETB) Throttle Position Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Firing Order Firing Order: Specifications Firing Order Firing Order.......................................................................................................................................... .........................................................................1-3-4-2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Firing Order > Page 3126 Firing Order: Specifications Engine Cylinder Identification Engine Engine Cylinder Identification Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3130 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3131 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The CMP sensor is a Hall-effect sensor that detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. The PCM also uses the CMP signal to select the correct ignition coil to fire. Typical Hall-effect CMP Sensor Camshaft Position (CMP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3132 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 3. NOTE: Lubricate the CMP sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3136 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3137 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates the 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. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between pulse wheel teeth. Typical Crankshaft Position (CKP) Sensor Crankshaft Position (CKP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3138 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts, the pin-type retainer (not shown) and the RH splash shield. 3. Turn the crankshaft clockwise until the hole in the crankshaft pulley is in the 3 o'clock position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3139 4. Remove the engine plug bolt. 5. NOTE: When the crankshaft contacts the Crankshaft TDC Timing Peg, the No. 1 cylinder will be at Top Dead Center (TDC). Install the Crankshaft TDC Timing Peg and turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg. 6. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 7. Remove the bolts and the CKP sensor. Installation 1. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6 mm x 18 mm bolt in the crankshaft pulley and thread it into the front cover. 2. Install the CKP sensor and the 2 bolts. - Do not tighten the bolts at this time. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3140 3. Adjust the CKP sensor with the Crankshaft Sensor Aligner. - Tighten the 2 CKP bolts to 7 Nm (62 lb-in). 4. Connect the CKP sensor electrical connector. 5. Remove the 6 mm x 18 mm bolt from the crankshaft pulley. 6. Install the engine plug bolt. - Tighten to 20 Nm (177 lb-in). 7. Install the RH splash shield, 5 bolts and the pin-type retainer (not shown). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3145 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3146 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3147 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3148 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3149 Ignition Coil: Description and Operation Coil On Plug (COP) The COPs are part of the distributorless ignition system. They are the source of the high voltage which is used to generate the spark by the spark plug. The hybrid vehicle uses four COPs, one for each cylinder. The COPs are mounted directly onto the spark plugs. The function of the COP is to convert low voltage into high voltage in excess of 40,000 volts. The COP consists of primary and secondary windings. The primary winding is energized by the IGN START/RUN circuit. The PCM coil driver circuit is connected to the primary winding as well. The secondary winding is connected to the spark plug. The current flowing through the primary winding generates the magnetic field across both windings. The PCM activates the coil driver circuit by opening it. The instant the circuit opens the magnetic field collapses, inducing current flow in the secondary winding. The COP has three different modes of operation: engine crank, engine running, and CMP failure mode effects management (FMEM). Typical Coil On Plug (COP) Coil On Plug Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Engine Ignition Components - Exploded View Ignition Coil: Service and Repair Engine Ignition Components - Exploded View Engine Ignition Components - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 3152 Ignition Coil: Service and Repair Ignition Coil-On-Plug Ignition Coil-On-Plug Removal and Installation 1. Disconnect the 4 ignition coil electrical connectors. 2. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal. Remove the 4 bolts and the ignition coils. - To install, tighten to 8 Nm (71 lb-in). 3. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals. - To install, slide the new coil seal onto the coil until fully seated at the top of the coil. 4. To install, reverse the removal procedure. - Apply a small amount of dielectric grease to the inside of the ignition coil boots before attaching to the spark plugs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3156 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3157 Knock Sensor: Description and Operation Knock Sensor (KS) The KS 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3158 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the intake manifold. 3. Remove the bolt and the Knock Sensor (KS). - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3163 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3164 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The CMP sensor is a Hall-effect sensor that detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. The PCM also uses the CMP signal to select the correct ignition coil to fire. Typical Hall-effect CMP Sensor Camshaft Position (CMP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3165 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 3. NOTE: Lubricate the CMP sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3169 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3170 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates the 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. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between pulse wheel teeth. Typical Crankshaft Position (CKP) Sensor Crankshaft Position (CKP) Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3171 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts, the pin-type retainer (not shown) and the RH splash shield. 3. Turn the crankshaft clockwise until the hole in the crankshaft pulley is in the 3 o'clock position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3172 4. Remove the engine plug bolt. 5. NOTE: When the crankshaft contacts the Crankshaft TDC Timing Peg, the No. 1 cylinder will be at Top Dead Center (TDC). Install the Crankshaft TDC Timing Peg and turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg. 6. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 7. Remove the bolts and the CKP sensor. Installation 1. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6 mm x 18 mm bolt in the crankshaft pulley and thread it into the front cover. 2. Install the CKP sensor and the 2 bolts. - Do not tighten the bolts at this time. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3173 3. Adjust the CKP sensor with the Crankshaft Sensor Aligner. - Tighten the 2 CKP bolts to 7 Nm (62 lb-in). 4. Connect the CKP sensor electrical connector. 5. Remove the 6 mm x 18 mm bolt from the crankshaft pulley. 6. Install the engine plug bolt. - Tighten to 20 Nm (177 lb-in). 7. Install the RH splash shield, 5 bolts and the pin-type retainer (not shown). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Removal and Installation NOTE: For non-functional ignition lock cylinders, the steering column lock module has to be replaced. 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3181 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3182 Knock Sensor: Description and Operation Knock Sensor (KS) The KS 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3183 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the intake manifold. 3. Remove the bolt and the Knock Sensor (KS). - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark plug gap..................................................................................................................................... ....................................1.08-1.18 mm (0.042-0.046 in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap > Page 3188 Spark Plug: Specifications Torque Specifications Spark plugs........................................................................................................................................... ........................................................12 Nm (106 lb-in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3189 Spark Plug: Application and ID Spark plug............................................................................................................................................ .............................................................AYSF-32-YPC Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3190 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. - Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. - Install a new spark plug. 2. Check for oil fouling. - Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. - Correct the oil leak concern. - Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. Install new spark plugs. 4. Inspect for normal burning. - Check for light tan or gray deposits on the firing tip. 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. Install a new spark plug. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3191 6. Inspect for overheating, identified by white or light gray spots and with a bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. - Install new spark plugs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View Spark Plug: Service and Repair Engine Ignition Components - Exploded View Engine Ignition Components - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 3194 Spark Plug: Service and Repair Spark Plugs Spark Plugs Removal and Installation 1. Remove the ignition coils. For additional information, refer to Ignition Coil-On-Plug See: Ignition Coil/Service and Repair/Ignition Coil-On-Plug. 2. NOTICE: Only use hand tools when removing or installing the spark plugs, or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material in the spark plug well prior to removing the spark plugs. Remove the spark plugs. - To install, tighten to 12 Nm (106 lb-in). 3. Inspect the spark plugs. 4. To install, reverse the removal procedure. - Adjust the spark plug gap as necessary. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 3201 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3209 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3210 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3211 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3212 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3213 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3214 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3215 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3216 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3217 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3218 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3219 Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3220 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3221 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3222 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3223 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3224 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3225 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3226 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3227 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3228 Control Module: Connector Views Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3229 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3230 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3231 Control Module: Electrical Diagrams Transaxle Control Module (TCM) 29-1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3232 29-2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Page 3233 Control Module: Testing and Inspection Transaxle Control Module (TCM) Reprogramming WARNING: THIS VEHICLE IS EQUIPPED WITH HIGH VOLTAGE CABLES, COMPONENTS, AND WIRING. THE HIGH VOLTAGE WARNING LABELS CONTAINING THE HIGH VOLTAGE SYMBOL ARE LOCATED ON EACH HIGH VOLTAGE COMPONENT. HIGH VOLTAGE CABLES AND WIRING ARE ORANGE IN COLOR. CERTIFIED RUBBER INSULATING GLOVES AND A FACE SHIELD MUST BE WORN WHEN WORKING WITH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING. THE IGNITION KEY MUST BE CYCLED TO THE OFF POSITION FOR A MINIMUM OF 5 MINUTES, AND THE HIGH VOLTAGE TRACTION BATTERY SERVICE DISCONNECT PLUG PLACED IN THE SERVICING/SHIPPING POSITION BEFORE DISCONNECTING THE HIGH VOLTAGE CABLES. DO NOT DISCONNECT, DISABLE, OR TOUCH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING DURING THE MODULE REPROGRAMMING PROCEDURE BECAUSE HIGH VOLTAGE IS PRESENT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH. Description Note: After the TCM is successfully reprogrammed clear the continuous diagnostic trouble codes (DTCs) in the powertrain control module (PCM) and the TCM that may have been stored during reprogramming. Changes made to the strategy or calibration may require TCM reprogramming. Refer to the Module Programming instructions on the scan tool. Making Changes To The TCM Calibration If the TCM does not complete the reflash after two consecutive attempts, follow the instructions listed below: 1. If the TCM reprogramming aborts during the procedure: - Reprogram the TCM again. - After the TCM reprogramming is successfully completed, clear the continuous DTCs in the PCM and the TCM. 2. If the TCM reprogramming aborts immediately after the start: - Turn the key OFF. - Disconnect the PCM body/cowl connector, and leave it disconnected. - Turn the key ON. - Start the TCM reprogramming. - After the TCM reprogramming is successfully completed, turn the key OFF and connect the PCM body/cowl connector. - Clear any PCM and TCM DTCs that may have been stored during reprogramming. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3238 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3239 Control Module: Service and Repair 4X4 Control Module Removal and Installation 1. Remove the floor console. 2. Disconnect the electrical connector. 3. Lift upward on the module to release the fasteners from the shifter base. Remove the 4X4 control module. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Mode Switch, CVT > Component Information > Diagrams Transmission Mode Switch: Diagrams Electrical Connectors C2096 (Vehicle Harness Side) C2096 (Component Side) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations Transmission Position Switch/Sensor: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 3248 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 3249 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 3250 Transmission Position Switch/Sensor: Description and Operation Transmission Range (TR) Sensor Overview The TR sensor communicates the gear selector position the driver selects to the PCM. The PCM determines a gear mode based on the TR input and the vehicle speed signal. The PCM then broadcasts a gear mode message over the communication link. The TCM uses the gear mode message to engage the transaxle in the gear the driver selected. The other control modules use the gear mode message to control the rear lamps or a brake shift interlock solenoid. The TR sensor is mounted at the base of the gear selector assembly and the sensor shaft is moved by the selector. Transmission Range (TR) Sensor TR Sensor and PCM Interface The TR sensor is a linear potentiometer device that provides the PCM with a percentage of input voltage proportional to the rotational angle of the sensor shaft. The TR sensor consists of: - two independent (TR-A1 and TR-A2) signals - two 5 volt reference (TR-VREF1 and TR-VREF2) lines - two signal return (TR-RTN1 and TR-RTN2) lines The TR-A1 signal has a negative voltage slope, meaning the voltage decreases when the sensor angle increases. The typical TR voltage ranges from approximately 4.3 volts in the PARK position to approximately 0.6 volt in the LOW gear position. The TR-A2 signal has a positive voltage slope. Voltages increase as the sensor angle increases. The typical voltage for the TR-A2 is about 1 volt in the PARK position to about 4.4 volts in the LOW gear position. The TR-VREF circuits are bussed together internal to the TR sensor, and both TR-RTN circuits are bussed together in the TR sensor. One of the TR-VREF and one of the TR-RTN circuits are dedicated signals from the PCM. This design of redundant signals protects against an open circuit condition. Voltage Versus Angle and Gear Selected Chart If the PCM detects a concern in one of TR signal inputs, it uses the other TR signal to determine what gear the driver selects. If the PCM detects one or more TR signals that are invalid, the PCM: - allows the vehicle to travel in DRIVE position or LOW gear position if the vehicle was driving forward at a significant speed when the concern was detected. - allows the vehicle to travel in REVERSE gear if the vehicle was driving backwards at a significant speed when the concern was detected. - broadcasts gear mode - NEUTRAL over the communication link when vehicle speed decreases to 8 km/h (5 mph). - sets the DTC and illuminates the indicator. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 PROM - Programmable Read Only Memory: Customer Interest Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 3259 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's P0442/P0456/P1450 TSB 10-1-3 02/01/10 HYBRID ONLY - DTCS P0442, P0456 OR P1450 - BUILT ON OR BEFORE 4/6/2009 FORD: 2010 Fusion 2009 Escape MERCURY: 2010 Milan 2009 Mariner This article supersedes TSB 09-9-9 to add a production fix date. ISSUE Some 2009 Escape Hybrid, Mariner Hybrid, 2010 Fusion Hybrid and Milan Hybrid vehicles built on or before 4/6/2009 may exhibit a malfunction indicator light (MIL) accompanied by diagnostic trouble code (DTC) P0442, P0456 or P1450. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Follow the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostic procedures for any DTC code that may be present to ensure the Evaporative Emissions (EVAP) system is functioning properly. 2. When performing EVAP diagnostics on Escape Hybrid and Mariner Hybrid vehicles, the ambient temperature must be greater than 32 °F (0 °C) and the heating ventilation air conditioning (HVAC) system should be set to Defrost. This will provide continuous gasoline engine operation. 3. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 60.11 and higher or 61.01 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 100103A 2010 Fusion Hybrid/Milan 0.3 Hr. Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) 100103A 2009 Escape 0.3 Hr. Hybrid/Mariner Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 3264 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 3270 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0442/P0456/P1450 TSB 10-1-3 02/01/10 HYBRID ONLY - DTCS P0442, P0456 OR P1450 - BUILT ON OR BEFORE 4/6/2009 FORD: 2010 Fusion 2009 Escape MERCURY: 2010 Milan 2009 Mariner This article supersedes TSB 09-9-9 to add a production fix date. ISSUE Some 2009 Escape Hybrid, Mariner Hybrid, 2010 Fusion Hybrid and Milan Hybrid vehicles built on or before 4/6/2009 may exhibit a malfunction indicator light (MIL) accompanied by diagnostic trouble code (DTC) P0442, P0456 or P1450. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Follow the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostic procedures for any DTC code that may be present to ensure the Evaporative Emissions (EVAP) system is functioning properly. 2. When performing EVAP diagnostics on Escape Hybrid and Mariner Hybrid vehicles, the ambient temperature must be greater than 32 °F (0 °C) and the heating ventilation air conditioning (HVAC) system should be set to Defrost. This will provide continuous gasoline engine operation. 3. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 60.11 and higher or 61.01 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 100103A 2010 Fusion Hybrid/Milan 0.3 Hr. Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) 100103A 2009 Escape 0.3 Hr. Hybrid/Mariner Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 3275 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls Sync Software Programming TSB 08-21-2 10/27/08 SYNC SOFTWARE PROGRAMMING SERVICE TIPS FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus 2009 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator 2009 Mark LT MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE The Sync Accessory Protocol Interface Module (APIM) may require updates to add system enhancements, improve system reliability or address consumer issues. The installation or availability of these updates may be made available in two different methods: ^ Downloadable consumer Service Pack updates available through www.SYNCmyride.com website. ^ APIM Programming Using the Integrated Diagnostic System (IDS). The tool and installation requirements vary between these two methods. This information is being provided to supplement current publications, clarify the requirements needed to reprogram or update the APIM module and provide some additional diagnostic/operational system information. ACTION Refer to the Service Tips for details. SERVICE TIPS Downloadable Consumer Service Pack Updates (Available At www.SyncMyRide.com) These Service Pack Updates are for the Consumer Interface Processor (CIP) side of the APIM module only and are customized for each vehicle based on the last reported APIM software level state. The software download process will bundle the appropriate service packs that are required to achieve the desired state. This is why consumers are asked to report back to the website once they have completed the install. NOTE IT IS NOT RECOMMENDED TO REUSE A DOWNLOADED SERVICE PACK ACROSS MULTIPLE VEHICLES. EACH DOWNLOAD IS PACKAGED ACCORDINGLY TO THE CURRENT STATE OF THE VEHICLE THAT THE DOWNLOAD IS INTENDED FOR. NOTE CONSUMERS DO NOT HAVE THE ABILITY TO REMOVE SERVICE PACK UPDATES ONCE THEY ARE INSTALLED. Steps For Consumer's To Update Sync With The Latest Enhancements 1. Prepare universal serial bus (USB) storage drive by: a. Log into their Sync account and select applications and updates to download. b. Locates a portable USB storage drive that they can take to their vehicle. NOTE FOR OWNERS OF MULTIPLE SYNC-EQUIPPED VEHICLES, IT IS STRONGLY RECOMMENDED TO USE A SEPARATE USB DRIVE FOR EACH SYNC-EQUIPPED VEHICLE. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3280 Dedicating a USB drive to each vehicle's Sync system helps keep each vehicle's download and installation history current and accurate. In addition, as new Sync features and functionalities become available, consumers may decide to install different features on different vehicles. Dedicated USB drives will help maintain the unique applications for each vehicle. 2. Download files by: a. Plug the USB drive into the computer's USB port. b. Select the USB port being used on the computer. c. Confirm choice of USB storage drive. Then click Next. d. After clicking Next, the files will automatically begin downloading. NOTE DO NOT REMOVE THE USB DRIVE UNTIL THE DOWNLOAD IS COMPLETE. THE SCREEN WILL CONFIRM THAT THE DOWNLOAD IS COMPLETE. e. Safely remove the USB storage drive from the computer's USB port by clicking on the Windows personal computer (PC) Safely Remove Hardware icon at the bottom right of the screen, next to the clock. 3. Install files by: a. Insert USB storage drive into the vehicle's Sync USB port. b. Turn on both, the vehicle and radio. NOTE IT IS RECOMMENDED TO HAVE THE VEHICLE RUNNING (WITH PROPER EXHAUST VENTILATION) AND NOT IN THE ACCESSORY MODE. THIS IS TO ENSURE THE VEHICLE'S BATTERY SUPPLY VOLTAGE REMAINS STABLE DURING THE PROGRAMMING PROCESS. c. Select User Device. d. Select Settings. e. Select Install. Display will change to Begin Installation? f. Select Yes. Installing file - will display on the screen. NOTE DO NOT REMOVE THE USB DRIVE WHILE THE INSTALLATION IS IN PROGRESS. g. Upon completion of downloading of files, Installation Complete will display on the Sync screen. h. The Sync voice will say, Installation complete. Sync may also say, The system will now reboot. Please wait a few moments before using the system. Installation Complete will remain on the Sync display until you exit the installation mode. i. Select the Menu radio button to exit installation mode. j. Remove the USB storage drive. k. Consumer takes their USB storage drive back to their computer to report the successful install. (This feature allows for tracking and determining if the consumers vehicle has a newer version available for downloading or not.) NOTE ADDITIONAL INFORMATION AND DETAILS ARE AVAILABLE ON THE SYNCMYRIDE.COM WEBSITE. REGISTERED SYNC OWNERS WILL SEE VEHICLE SPECIFIC DETAILS AND DIRECTIONS BASED ON THEIR VEHICLE'S OPTION CONTENT. APIM Programming Using IDS This method programs both, the Vehicle Interface Processor (VIP) (through the data link connector) and CIP (through the USB port), portions of the APIM module. NOTE Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3281 SOFTWARE PACKAGES OBTAINED THROUGH THE PROFESSIONAL TECHNICIAN SOCIETY (PTS) WEBSITE CONTAINS BOTH, VIP AND CIP FILES, THESE DO NOT NEED TO BE INSTALLED IN SEQUENCE LIKE THE CONSUMER DOWNLOAD SERVICE PACK UPDATES, BUT THE ENTIRE PACKAGE MUST BE INSTALLED DURING REPROGRAMMING FOR PROPER OPERATION. THESE SOFTWARE PACKAGES ARE MUCH LARGER IN SIZE AND CONTAIN ALL THE PREVIOUS LEVELS OF ENHANCEMENTS AND UPDATES AS WELL AS ANY ADDITIONAL ENHANCEMENTS AND UPDATES FOR BOTH THE VIP AND CIP PROCESSORS LOCATED IN THE APIM MODULE. NOTE YOU WILL NOT HAVE THE ABILITY TO RESTORE THE PREVIOUS LEVEL OF SYNC OPERATING SOFTWARE ONCE THE APIM MODULE HAS BEEN SUCCESSFULLY UPDATED TO THE NEXT HIGHER LEVEL. NOTE If a new APIM is being installed, install the new APIM before carrying out the following procedure. For additional information, refer to Workshop Manual (WSM), Section 415-00. It is recommended to install a battery charger to the vehicles battery and set at the low charge setting and insure the PC being used for reprogramming is fully charged or plugged into a power source prior to starting the reprogramming process. 1. Turn the ignition key to the On position. 2. Turn the audio control module (ACM) on. 3. Connect the scan tool to the data link connector (DLC). 4. Connect one end of the USB male-A to male-A cable Rotunda part number CCMUSB2-AM-AM-10 (1-800-Rotunda option 6) or equivalent to the scan tool. Compatible cables. (Figures 1) Non-compatible cables. (Figure 2) 5. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 6. From the technician service publication website, run OASIS using Quick Start or by manually entering the vehicle identification number (VIN). 7. From the OASIS tab, select the Sync/APIM bullet. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3282 8. Select the Read APIM button to verify the current APIM VIP and CIP software levels. NOTE DO NOT DISCONNECT THE VEHICLE COMMUNICATION MODULE (VCM) OR USB CABLES DURING APIM PROGRAMMING. 9. Select the desired software level from the list of available software for programming then select the Program APIM button to begin the APIM programming process. Enter the APIM As-Built data if prompted. a. When only the CIP is being programmed, select cancel when prompted whether or not to program the VIP. b. When the VIP is programmed, the CIP will be programmed automatically. 10. The Sync/APIM application downloads the software into the APIM and displays Programming has been completed successfully. 11. Test the audio system for correct operation. PC requirements for successful reprogramming an APIM module. Ford And LIM Logon Issues - Including Proper Browser Settings The following list will have you check various computer settings to insure your PC is set to the proper configuration for reprogramming an APIM module. NOTE CHANGES TO PC SETTINGS MAY REQUIRE ADMINISTRATOR ACCESS. 1. Do not use a customized browser like AOL, it will not work. Please use Internet Explorer (IE) version 5.5 5P2, 6.0, or higher. 2. Log into website. 3. Navigate to PTS (Professional Technician Society) under the Technical Tools on the Parts and Service tab. 4. Check IE settings by completing the following: a. Preliminary Checks. NOTE THESE INSTRUCTIONS APPLY TO WINDOWS XP MACHINES WITH 5P2 AND IE 6.0 AND ABOVE. (1) Open IE, select Tools at the top of the screen and select Security. (2) Click on the Internet Zone, and find Navigate Sub-frames across different domains and enable this function. (3) Then click OK, system may ask you if you want to accept these function please select Yes. (4) Check the Windows Firewall to make sure it is turned off by: (a) Selecting the Start button. (b) Select Control Panel. (c) Select Windows Firewall (if you do not see the icon, make sure you are using Classic View) and set to off. (5) Check Windows Pop-up Blocker to make sure it is turned off. (a) Open IE. (b) Select Tools at the top of the screen. (c) Select Pop-up Blocker and turn it off. (6) Remove any add-on toolbars such as Google or Yahoo toolbars, as these have additional built in pop-up blockers. (7) Verify that any third party anti-virus, anti-spyware, firewall, or internet security software is temporarily disabled. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3283 b. Browser Settings - Open IE and select Internet Options under the Tools heading. (1) Select the General tab (2) Select Delete Files and check the Delete all offline content and select OK (3) Select Delete Cookies and click OK (4) Select Clear History and select Yes. (5) Click on the Security tab. (6) Click on the Trusted Sites icon. (7) Click on Sites. (8) In the box below add this website to the zone type in - website. (9) Ensure that required server verification (https:) for all sites in this zone is not checked. (10) Click the Add button. (11) Click the Close button. (12) Re-select the Security tab and select Custom Level. (13) Under Reset Custom Settings, pull down and Reset to: Low, select Reset, select Yes and then OK. NOTE IF RUNNING OASIS ON IE 7.0, RESET TO: MEDIUM-LOW. ALSO, UNDER SETTINGS, SCROLL TO NAVIGATE SUB-FRAMES ACROSS DIFFERENT DOMAINS, SET TO ENABLED AND CLICK OK. (14) Select the Privacy tab, and move the slider to Low. (15) Click on the Advanced, check the box Override automatic cookie handling and check the box to Always allow session cookies' and click OK. (16) Select the Advanced tab and scroll down to HTP 1.1 settings; make sure both options under this section are checked. (17) Scroll down to Security section and make sure the following are checked: (a) Empty Temporary Internet folder when browser is closed. (b) Use SSL 2.0. (c) Use SSL 3.0. (d) Use TLS 1.0. (e) Select Apply and then click on OK. 5. Close all browsers and reboot the computer to have the browser settings take affect properly. The browser settings have now been setup correctly as per Ford Browser settings recommendations. Additional PC Security Settings (May Or May Not Be Required - Depends On Operating System) Changes to PC Security Settings may require Administrator access. 1. Check for Information Bar near top of IE page stating - This website wants to run the following add-ons. 2. Click on Information Bar and select Run ActiveX Controls or Temporarily Allow Pop-ups depending on your operating system. 3. Click on Retry button to refresh information. (May not be required on some operating systems) PC and Server Troubleshooting (Optional) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3284 ^ If you wish to test another browser for web-based training only, download the free version of Opera at www.Opera.com. ^ For web-based training sound problems, make sure your firewall allows downloading sound file types such as MP3. ^ If you have installed special search and add-on programs such as Gator or Bonzi please remove them. ^ If you have a router, make sure that port 443 is open for Secure Socket Layer (SSL), and ports 80 and 8080 are open for HTTP. ^ Internet access uses a caching or proxy server. Make sure the caching/proxy servers are set to automatically detect settings. Contact your local network administrator and/or your Internet service provider and have them turn off the caching on any and all caching proxy servers for the following: ^ Uniform Resource Locator (URL): www.proservicetech.com or ford website Additional Sync Related Service Tips 1. Performing a Master Reset of the APIM module or removing and restoring the Keep Alive Power circuit fuse (refer to the appropriate wiring manual) for 3-minutes, prior to reprogramming will restore the factory APIM defaults. This can reduce the possibilities of corrupt files, that may have been transferred into the APIM modules memory, from interfering with the reprogramming of the CIP portion of the APIM module. 2. Non-factory installed items that can cause background noise, wind noise or obstruct the voice path to the Sync system's microphone, will reduce the reliability or accuracy of the consumer's voice commands or speech being recognized properly. Some examples may include but are not limited to: ^ Objects hanging from the rear view mirror that may make noise or obstruct the system microphone located on the mirror. ^ Bug shields. ^ Roof mounted accessories. ^ Damaged window moldings. ^ Non-factory installed overhead consoles or sun-visor storage compartments that obstruct the voice path to the systems microphone. (It is recommended when diagnosing voice recognition or phone call sound quality issues to eliminate these types of items before replacing any system components) 3. Remote Starts may prevent the Automatic Discovery Process, of previously paired phones, from connecting with the consumer's phone as it may be outside of the device's Bluetooth reception range. Once the vehicle is started remotely, the Sync system automatically begins to search for previously paired phones; eventually this process will time out if the customers phone does not enter the vehicle prior to the expiration of this internal timer, resulting in the vehicle Sync not automatically recognize the phone and pair with it. If this occurs, once the customer enters the vehicle, the consumer will be required to manually connect the phone through the Sync menus if they would like to use the hands free phone features. NOTE THE CONSUMER WILL NOT BE REQUIRED TO PAIR THE PHONE AGAIN. 4. When Reprogramming APIM modules, it is strongly recommended to use a hard wired internet connection if possible, due to the APIM program file sizes. If a wired internet connection is not available, it is recommended to access the PTS website and download the latest Sync software files from the Tech Central tab prior to reprogramming. This will reduce the overall reprogramming time when you are connected to the vehicle. If error messages appear during the reprogramming process that indicate errors with the VIP or CIP file/image, comparing the saved file/image by checking the file size, between your PC/IDS with the available file/image size indicated in the PTS description can help determine if the file may be corrupt or damaged. If this has occurred or is suspected, re-download the file/image and select Yes when asked Do you want to replace it? 5. Always diagnose and repair any DTC's for the Audio system or any module communication related faults prior to APIM reprogramming. WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls Sync Software Programming TSB 08-21-2 10/27/08 SYNC SOFTWARE PROGRAMMING SERVICE TIPS FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus 2009 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator 2009 Mark LT MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE The Sync Accessory Protocol Interface Module (APIM) may require updates to add system enhancements, improve system reliability or address consumer issues. The installation or availability of these updates may be made available in two different methods: ^ Downloadable consumer Service Pack updates available through www.SYNCmyride.com website. ^ APIM Programming Using the Integrated Diagnostic System (IDS). The tool and installation requirements vary between these two methods. This information is being provided to supplement current publications, clarify the requirements needed to reprogram or update the APIM module and provide some additional diagnostic/operational system information. ACTION Refer to the Service Tips for details. SERVICE TIPS Downloadable Consumer Service Pack Updates (Available At www.SyncMyRide.com) These Service Pack Updates are for the Consumer Interface Processor (CIP) side of the APIM module only and are customized for each vehicle based on the last reported APIM software level state. The software download process will bundle the appropriate service packs that are required to achieve the desired state. This is why consumers are asked to report back to the website once they have completed the install. NOTE IT IS NOT RECOMMENDED TO REUSE A DOWNLOADED SERVICE PACK ACROSS MULTIPLE VEHICLES. EACH DOWNLOAD IS PACKAGED ACCORDINGLY TO THE CURRENT STATE OF THE VEHICLE THAT THE DOWNLOAD IS INTENDED FOR. NOTE CONSUMERS DO NOT HAVE THE ABILITY TO REMOVE SERVICE PACK UPDATES ONCE THEY ARE INSTALLED. Steps For Consumer's To Update Sync With The Latest Enhancements 1. Prepare universal serial bus (USB) storage drive by: a. Log into their Sync account and select applications and updates to download. b. Locates a portable USB storage drive that they can take to their vehicle. NOTE FOR OWNERS OF MULTIPLE SYNC-EQUIPPED VEHICLES, IT IS STRONGLY RECOMMENDED TO USE A SEPARATE USB DRIVE FOR EACH SYNC-EQUIPPED VEHICLE. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3290 Dedicating a USB drive to each vehicle's Sync system helps keep each vehicle's download and installation history current and accurate. In addition, as new Sync features and functionalities become available, consumers may decide to install different features on different vehicles. Dedicated USB drives will help maintain the unique applications for each vehicle. 2. Download files by: a. Plug the USB drive into the computer's USB port. b. Select the USB port being used on the computer. c. Confirm choice of USB storage drive. Then click Next. d. After clicking Next, the files will automatically begin downloading. NOTE DO NOT REMOVE THE USB DRIVE UNTIL THE DOWNLOAD IS COMPLETE. THE SCREEN WILL CONFIRM THAT THE DOWNLOAD IS COMPLETE. e. Safely remove the USB storage drive from the computer's USB port by clicking on the Windows personal computer (PC) Safely Remove Hardware icon at the bottom right of the screen, next to the clock. 3. Install files by: a. Insert USB storage drive into the vehicle's Sync USB port. b. Turn on both, the vehicle and radio. NOTE IT IS RECOMMENDED TO HAVE THE VEHICLE RUNNING (WITH PROPER EXHAUST VENTILATION) AND NOT IN THE ACCESSORY MODE. THIS IS TO ENSURE THE VEHICLE'S BATTERY SUPPLY VOLTAGE REMAINS STABLE DURING THE PROGRAMMING PROCESS. c. Select User Device. d. Select Settings. e. Select Install. Display will change to Begin Installation? f. Select Yes. Installing file - will display on the screen. NOTE DO NOT REMOVE THE USB DRIVE WHILE THE INSTALLATION IS IN PROGRESS. g. Upon completion of downloading of files, Installation Complete will display on the Sync screen. h. The Sync voice will say, Installation complete. Sync may also say, The system will now reboot. Please wait a few moments before using the system. Installation Complete will remain on the Sync display until you exit the installation mode. i. Select the Menu radio button to exit installation mode. j. Remove the USB storage drive. k. Consumer takes their USB storage drive back to their computer to report the successful install. (This feature allows for tracking and determining if the consumers vehicle has a newer version available for downloading or not.) NOTE ADDITIONAL INFORMATION AND DETAILS ARE AVAILABLE ON THE SYNCMYRIDE.COM WEBSITE. REGISTERED SYNC OWNERS WILL SEE VEHICLE SPECIFIC DETAILS AND DIRECTIONS BASED ON THEIR VEHICLE'S OPTION CONTENT. APIM Programming Using IDS This method programs both, the Vehicle Interface Processor (VIP) (through the data link connector) and CIP (through the USB port), portions of the APIM module. NOTE Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3291 SOFTWARE PACKAGES OBTAINED THROUGH THE PROFESSIONAL TECHNICIAN SOCIETY (PTS) WEBSITE CONTAINS BOTH, VIP AND CIP FILES, THESE DO NOT NEED TO BE INSTALLED IN SEQUENCE LIKE THE CONSUMER DOWNLOAD SERVICE PACK UPDATES, BUT THE ENTIRE PACKAGE MUST BE INSTALLED DURING REPROGRAMMING FOR PROPER OPERATION. THESE SOFTWARE PACKAGES ARE MUCH LARGER IN SIZE AND CONTAIN ALL THE PREVIOUS LEVELS OF ENHANCEMENTS AND UPDATES AS WELL AS ANY ADDITIONAL ENHANCEMENTS AND UPDATES FOR BOTH THE VIP AND CIP PROCESSORS LOCATED IN THE APIM MODULE. NOTE YOU WILL NOT HAVE THE ABILITY TO RESTORE THE PREVIOUS LEVEL OF SYNC OPERATING SOFTWARE ONCE THE APIM MODULE HAS BEEN SUCCESSFULLY UPDATED TO THE NEXT HIGHER LEVEL. NOTE If a new APIM is being installed, install the new APIM before carrying out the following procedure. For additional information, refer to Workshop Manual (WSM), Section 415-00. It is recommended to install a battery charger to the vehicles battery and set at the low charge setting and insure the PC being used for reprogramming is fully charged or plugged into a power source prior to starting the reprogramming process. 1. Turn the ignition key to the On position. 2. Turn the audio control module (ACM) on. 3. Connect the scan tool to the data link connector (DLC). 4. Connect one end of the USB male-A to male-A cable Rotunda part number CCMUSB2-AM-AM-10 (1-800-Rotunda option 6) or equivalent to the scan tool. Compatible cables. (Figures 1) Non-compatible cables. (Figure 2) 5. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 6. From the technician service publication website, run OASIS using Quick Start or by manually entering the vehicle identification number (VIN). 7. From the OASIS tab, select the Sync/APIM bullet. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3292 8. Select the Read APIM button to verify the current APIM VIP and CIP software levels. NOTE DO NOT DISCONNECT THE VEHICLE COMMUNICATION MODULE (VCM) OR USB CABLES DURING APIM PROGRAMMING. 9. Select the desired software level from the list of available software for programming then select the Program APIM button to begin the APIM programming process. Enter the APIM As-Built data if prompted. a. When only the CIP is being programmed, select cancel when prompted whether or not to program the VIP. b. When the VIP is programmed, the CIP will be programmed automatically. 10. The Sync/APIM application downloads the software into the APIM and displays Programming has been completed successfully. 11. Test the audio system for correct operation. PC requirements for successful reprogramming an APIM module. Ford And LIM Logon Issues - Including Proper Browser Settings The following list will have you check various computer settings to insure your PC is set to the proper configuration for reprogramming an APIM module. NOTE CHANGES TO PC SETTINGS MAY REQUIRE ADMINISTRATOR ACCESS. 1. Do not use a customized browser like AOL, it will not work. Please use Internet Explorer (IE) version 5.5 5P2, 6.0, or higher. 2. Log into website. 3. Navigate to PTS (Professional Technician Society) under the Technical Tools on the Parts and Service tab. 4. Check IE settings by completing the following: a. Preliminary Checks. NOTE THESE INSTRUCTIONS APPLY TO WINDOWS XP MACHINES WITH 5P2 AND IE 6.0 AND ABOVE. (1) Open IE, select Tools at the top of the screen and select Security. (2) Click on the Internet Zone, and find Navigate Sub-frames across different domains and enable this function. (3) Then click OK, system may ask you if you want to accept these function please select Yes. (4) Check the Windows Firewall to make sure it is turned off by: (a) Selecting the Start button. (b) Select Control Panel. (c) Select Windows Firewall (if you do not see the icon, make sure you are using Classic View) and set to off. (5) Check Windows Pop-up Blocker to make sure it is turned off. (a) Open IE. (b) Select Tools at the top of the screen. (c) Select Pop-up Blocker and turn it off. (6) Remove any add-on toolbars such as Google or Yahoo toolbars, as these have additional built in pop-up blockers. (7) Verify that any third party anti-virus, anti-spyware, firewall, or internet security software is temporarily disabled. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3293 b. Browser Settings - Open IE and select Internet Options under the Tools heading. (1) Select the General tab (2) Select Delete Files and check the Delete all offline content and select OK (3) Select Delete Cookies and click OK (4) Select Clear History and select Yes. (5) Click on the Security tab. (6) Click on the Trusted Sites icon. (7) Click on Sites. (8) In the box below add this website to the zone type in - website. (9) Ensure that required server verification (https:) for all sites in this zone is not checked. (10) Click the Add button. (11) Click the Close button. (12) Re-select the Security tab and select Custom Level. (13) Under Reset Custom Settings, pull down and Reset to: Low, select Reset, select Yes and then OK. NOTE IF RUNNING OASIS ON IE 7.0, RESET TO: MEDIUM-LOW. ALSO, UNDER SETTINGS, SCROLL TO NAVIGATE SUB-FRAMES ACROSS DIFFERENT DOMAINS, SET TO ENABLED AND CLICK OK. (14) Select the Privacy tab, and move the slider to Low. (15) Click on the Advanced, check the box Override automatic cookie handling and check the box to Always allow session cookies' and click OK. (16) Select the Advanced tab and scroll down to HTP 1.1 settings; make sure both options under this section are checked. (17) Scroll down to Security section and make sure the following are checked: (a) Empty Temporary Internet folder when browser is closed. (b) Use SSL 2.0. (c) Use SSL 3.0. (d) Use TLS 1.0. (e) Select Apply and then click on OK. 5. Close all browsers and reboot the computer to have the browser settings take affect properly. The browser settings have now been setup correctly as per Ford Browser settings recommendations. Additional PC Security Settings (May Or May Not Be Required - Depends On Operating System) Changes to PC Security Settings may require Administrator access. 1. Check for Information Bar near top of IE page stating - This website wants to run the following add-ons. 2. Click on Information Bar and select Run ActiveX Controls or Temporarily Allow Pop-ups depending on your operating system. 3. Click on Retry button to refresh information. (May not be required on some operating systems) PC and Server Troubleshooting (Optional) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3294 ^ If you wish to test another browser for web-based training only, download the free version of Opera at www.Opera.com. ^ For web-based training sound problems, make sure your firewall allows downloading sound file types such as MP3. ^ If you have installed special search and add-on programs such as Gator or Bonzi please remove them. ^ If you have a router, make sure that port 443 is open for Secure Socket Layer (SSL), and ports 80 and 8080 are open for HTTP. ^ Internet access uses a caching or proxy server. Make sure the caching/proxy servers are set to automatically detect settings. Contact your local network administrator and/or your Internet service provider and have them turn off the caching on any and all caching proxy servers for the following: ^ Uniform Resource Locator (URL): www.proservicetech.com or ford website Additional Sync Related Service Tips 1. Performing a Master Reset of the APIM module or removing and restoring the Keep Alive Power circuit fuse (refer to the appropriate wiring manual) for 3-minutes, prior to reprogramming will restore the factory APIM defaults. This can reduce the possibilities of corrupt files, that may have been transferred into the APIM modules memory, from interfering with the reprogramming of the CIP portion of the APIM module. 2. Non-factory installed items that can cause background noise, wind noise or obstruct the voice path to the Sync system's microphone, will reduce the reliability or accuracy of the consumer's voice commands or speech being recognized properly. Some examples may include but are not limited to: ^ Objects hanging from the rear view mirror that may make noise or obstruct the system microphone located on the mirror. ^ Bug shields. ^ Roof mounted accessories. ^ Damaged window moldings. ^ Non-factory installed overhead consoles or sun-visor storage compartments that obstruct the voice path to the systems microphone. (It is recommended when diagnosing voice recognition or phone call sound quality issues to eliminate these types of items before replacing any system components) 3. Remote Starts may prevent the Automatic Discovery Process, of previously paired phones, from connecting with the consumer's phone as it may be outside of the device's Bluetooth reception range. Once the vehicle is started remotely, the Sync system automatically begins to search for previously paired phones; eventually this process will time out if the customers phone does not enter the vehicle prior to the expiration of this internal timer, resulting in the vehicle Sync not automatically recognize the phone and pair with it. If this occurs, once the customer enters the vehicle, the consumer will be required to manually connect the phone through the Sync menus if they would like to use the hands free phone features. NOTE THE CONSUMER WILL NOT BE REQUIRED TO PAIR THE PHONE AGAIN. 4. When Reprogramming APIM modules, it is strongly recommended to use a hard wired internet connection if possible, due to the APIM program file sizes. If a wired internet connection is not available, it is recommended to access the PTS website and download the latest Sync software files from the Tech Central tab prior to reprogramming. This will reduce the overall reprogramming time when you are connected to the vehicle. If error messages appear during the reprogramming process that indicate errors with the VIP or CIP file/image, comparing the saved file/image by checking the file size, between your PC/IDS with the available file/image size indicated in the PTS description can help determine if the file may be corrupt or damaged. If this has occurred or is suspected, re-download the file/image and select Yes when asked Do you want to replace it? 5. Always diagnose and repair any DTC's for the Audio system or any module communication related faults prior to APIM reprogramming. WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 3301 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > A/T - Vehicle Flat Towing Guidelines Automatic Transmission Dipstick - Dipstick Tube: Technical Service Bulletins A/T - Vehicle Flat Towing Guidelines TSB 09-20-13 10/19/09 6F35 TRANSMISSION - RECREATIONAL TOWING - VEHICLE WITH ALL 4 WHEELS ON THE GROUND - EXPANDED GUIDELINES TO PREVENT TRANSMISSION DAMAGE FORD: 2010 Fusion 2009-2010 Escape MERCURY: 2010 Milan 2009-2010 Mariner ISSUE Some 2009-2010 Escape, Mariner, 2010 Fusion and Milan vehicles equipped with a 6F35 automatic transmission, may experience transmission shift concerns after towing the vehicle with all 4 wheels on the ground (Flat tow) such as behind a motor home or a truck. The transmission shift concern may be caused by heat build up in the transmission due to the transmission fluid level being too high, towing speeds above 65 MPH (105 Km/h) and/or not stopping to run the engine at idle for 5 minutes every six hours or less, to cool the transmission. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE There are specific instructions listed in the Owner Guide that must be followed to recreational tow/flat tow/tow a vehicle with all 4 tires on the ground. Advise customers of the following expanded recreational towing guidelines. 1. Transmission fluid level must be checked at operating temperature of 185 °F - 200 °F (85 °C - 93 °C), per Workshop Manual (WSM), Section 307-01. At this temperature, adjust fluid level between minimum line and the minimum hole at the bottom of the hash marks on dipstick. This level is within the safe operating fluid level and does not require the customer to have the fluid level readjusted after flat tow operation. (Figure 1) 2. Maximum towing speed is 65 MPH (105 Km/h). 3. Do not flat tow the vehicle for greater than 6 hours at a time. 4. Start and run the engine for: a. 5 minutes before towing each day b. 5 minutes every 6 hours or less. c. While running the engine at idle for 5 minutes, with foot on the brake, shift through all gears. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > A/T - Vehicle Flat Towing Guidelines > Page 3307 These guidelines are designed to prevent damage to the transmission due to overheating. If setting the fluid level for a customer that will be recreational (flat) towing the vehicle, set the level between minimum line and the minimum hole at the bottom of the hash marks on dipstick (Figure 1) per WSM Section 307-01. NOTE THERE IS A SIGNIFICANT DIFFERENCE IN TRANSMISSION DIPSTICK READINGS BETWEEN A COLD TRANSMISSION AND A TRANSMISSION AT OPERATING TEMPERATURE. FAILURE TO CHECK TRANS FLUID LEVEL AT TRANS OPERATING TEMPERATURE, PER WSM SECTION 307-01 MAY RESULT IN DAMAGE TO THE TRANSMISSION. If the vehicle is a 2009 Escape or Mariner and built on or before 10/28/2008 the dipstick does not have Minimum - Maximum lines outside of hash marks, then replace dipstick. 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 MT092013 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 7000 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Vehicle Flat Towing Guidelines Fluid - A/T: Technical Service Bulletins A/T - Vehicle Flat Towing Guidelines TSB 09-20-13 10/19/09 6F35 TRANSMISSION - RECREATIONAL TOWING - VEHICLE WITH ALL 4 WHEELS ON THE GROUND - EXPANDED GUIDELINES TO PREVENT TRANSMISSION DAMAGE FORD: 2010 Fusion 2009-2010 Escape MERCURY: 2010 Milan 2009-2010 Mariner ISSUE Some 2009-2010 Escape, Mariner, 2010 Fusion and Milan vehicles equipped with a 6F35 automatic transmission, may experience transmission shift concerns after towing the vehicle with all 4 wheels on the ground (Flat tow) such as behind a motor home or a truck. The transmission shift concern may be caused by heat build up in the transmission due to the transmission fluid level being too high, towing speeds above 65 MPH (105 Km/h) and/or not stopping to run the engine at idle for 5 minutes every six hours or less, to cool the transmission. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE There are specific instructions listed in the Owner Guide that must be followed to recreational tow/flat tow/tow a vehicle with all 4 tires on the ground. Advise customers of the following expanded recreational towing guidelines. 1. Transmission fluid level must be checked at operating temperature of 185 °F - 200 °F (85 °C - 93 °C), per Workshop Manual (WSM), Section 307-01. At this temperature, adjust fluid level between minimum line and the minimum hole at the bottom of the hash marks on dipstick. This level is within the safe operating fluid level and does not require the customer to have the fluid level readjusted after flat tow operation. (Figure 1) 2. Maximum towing speed is 65 MPH (105 Km/h). 3. Do not flat tow the vehicle for greater than 6 hours at a time. 4. Start and run the engine for: a. 5 minutes before towing each day b. 5 minutes every 6 hours or less. c. While running the engine at idle for 5 minutes, with foot on the brake, shift through all gears. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Vehicle Flat Towing Guidelines > Page 3312 These guidelines are designed to prevent damage to the transmission due to overheating. If setting the fluid level for a customer that will be recreational (flat) towing the vehicle, set the level between minimum line and the minimum hole at the bottom of the hash marks on dipstick (Figure 1) per WSM Section 307-01. NOTE THERE IS A SIGNIFICANT DIFFERENCE IN TRANSMISSION DIPSTICK READINGS BETWEEN A COLD TRANSMISSION AND A TRANSMISSION AT OPERATING TEMPERATURE. FAILURE TO CHECK TRANS FLUID LEVEL AT TRANS OPERATING TEMPERATURE, PER WSM SECTION 307-01 MAY RESULT IN DAMAGE TO THE TRANSMISSION. If the vehicle is a 2009 Escape or Mariner and built on or before 10/28/2008 the dipstick does not have Minimum - Maximum lines outside of hash marks, then replace dipstick. 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 MT092013 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 7000 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3319 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3320 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3321 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3322 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3323 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3324 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3325 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3326 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3327 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3328 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3329 Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3330 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3331 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3332 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3333 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3334 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3335 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3336 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3337 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3338 Control Module: Connector Views Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3339 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3340 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3341 Control Module: Electrical Diagrams Transaxle Control Module (TCM) 29-1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3342 29-2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Page 3343 Control Module: Testing and Inspection Transaxle Control Module (TCM) Reprogramming WARNING: THIS VEHICLE IS EQUIPPED WITH HIGH VOLTAGE CABLES, COMPONENTS, AND WIRING. THE HIGH VOLTAGE WARNING LABELS CONTAINING THE HIGH VOLTAGE SYMBOL ARE LOCATED ON EACH HIGH VOLTAGE COMPONENT. HIGH VOLTAGE CABLES AND WIRING ARE ORANGE IN COLOR. CERTIFIED RUBBER INSULATING GLOVES AND A FACE SHIELD MUST BE WORN WHEN WORKING WITH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING. THE IGNITION KEY MUST BE CYCLED TO THE OFF POSITION FOR A MINIMUM OF 5 MINUTES, AND THE HIGH VOLTAGE TRACTION BATTERY SERVICE DISCONNECT PLUG PLACED IN THE SERVICING/SHIPPING POSITION BEFORE DISCONNECTING THE HIGH VOLTAGE CABLES. DO NOT DISCONNECT, DISABLE, OR TOUCH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING DURING THE MODULE REPROGRAMMING PROCEDURE BECAUSE HIGH VOLTAGE IS PRESENT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH. Description Note: After the TCM is successfully reprogrammed clear the continuous diagnostic trouble codes (DTCs) in the powertrain control module (PCM) and the TCM that may have been stored during reprogramming. Changes made to the strategy or calibration may require TCM reprogramming. Refer to the Module Programming instructions on the scan tool. Making Changes To The TCM Calibration If the TCM does not complete the reflash after two consecutive attempts, follow the instructions listed below: 1. If the TCM reprogramming aborts during the procedure: - Reprogram the TCM again. - After the TCM reprogramming is successfully completed, clear the continuous DTCs in the PCM and the TCM. 2. If the TCM reprogramming aborts immediately after the start: - Turn the key OFF. - Disconnect the PCM body/cowl connector, and leave it disconnected. - Turn the key ON. - Start the TCM reprogramming. - After the TCM reprogramming is successfully completed, turn the key OFF and connect the PCM body/cowl connector. - Clear any PCM and TCM DTCs that may have been stored during reprogramming. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Specifications > Capacity Specifications Fluid - CVT: Capacity Specifications Fluid Capacities Transmission Fluid............................................................................................................................... ....................................................4.05L (4.28 quarts)* Motor electronics cooling system......................................................................................................... ......................................................3.5L (3.7 quarts)** * Note: Transmission filled for life. The correct transaxle fill level is to the bottom of the fill plug, which is the upper plug. ** Note: Approximate dry fill capacity Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Specifications > Capacity Specifications > Page 3348 Fluid - CVT: Fluid Type Specifications Ford Part Name - Mercon LV Automatic Transmission Fluid Ford Part Number - XT-10-QLV Ford Specification - MERCON LV Note: Using any transmission fluid other than those that meet the recommended specification may cause internal transmission damage. Ford Part Name - Motorcraft Premium Gold Engine Coolant Ford Part Number - VC-7-B (US) - CVC-7-A (Canada) - Or equivalent Ford Specification - WSS-M97B51-A1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Pump, CVT > Component Information > Service and Repair Fluid Pump: Service and Repair Motor Electronics Pump 1. Drain the motor electronics cooling system (MECS). For additional information, refer to See: Service and Repair/Procedures 2. Disconnect the inlet and outlet hoses. ^ Disconnect the harness connector. 3. Remove the bolts. ^ To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3358 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3359 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3360 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3361 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3362 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3363 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3364 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3365 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3366 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3367 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3368 Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3369 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3370 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3371 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3372 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3373 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3374 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3375 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3376 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3377 Control Module: Connector Views Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3378 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3379 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3380 Control Module: Electrical Diagrams Transaxle Control Module (TCM) 29-1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3381 29-2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Page 3382 Control Module: Testing and Inspection Transaxle Control Module (TCM) Reprogramming WARNING: THIS VEHICLE IS EQUIPPED WITH HIGH VOLTAGE CABLES, COMPONENTS, AND WIRING. THE HIGH VOLTAGE WARNING LABELS CONTAINING THE HIGH VOLTAGE SYMBOL ARE LOCATED ON EACH HIGH VOLTAGE COMPONENT. HIGH VOLTAGE CABLES AND WIRING ARE ORANGE IN COLOR. CERTIFIED RUBBER INSULATING GLOVES AND A FACE SHIELD MUST BE WORN WHEN WORKING WITH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING. THE IGNITION KEY MUST BE CYCLED TO THE OFF POSITION FOR A MINIMUM OF 5 MINUTES, AND THE HIGH VOLTAGE TRACTION BATTERY SERVICE DISCONNECT PLUG PLACED IN THE SERVICING/SHIPPING POSITION BEFORE DISCONNECTING THE HIGH VOLTAGE CABLES. DO NOT DISCONNECT, DISABLE, OR TOUCH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING DURING THE MODULE REPROGRAMMING PROCEDURE BECAUSE HIGH VOLTAGE IS PRESENT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH. Description Note: After the TCM is successfully reprogrammed clear the continuous diagnostic trouble codes (DTCs) in the powertrain control module (PCM) and the TCM that may have been stored during reprogramming. Changes made to the strategy or calibration may require TCM reprogramming. Refer to the Module Programming instructions on the scan tool. Making Changes To The TCM Calibration If the TCM does not complete the reflash after two consecutive attempts, follow the instructions listed below: 1. If the TCM reprogramming aborts during the procedure: - Reprogram the TCM again. - After the TCM reprogramming is successfully completed, clear the continuous DTCs in the PCM and the TCM. 2. If the TCM reprogramming aborts immediately after the start: - Turn the key OFF. - Disconnect the PCM body/cowl connector, and leave it disconnected. - Turn the key ON. - Start the TCM reprogramming. - After the TCM reprogramming is successfully completed, turn the key OFF and connect the PCM body/cowl connector. - Clear any PCM and TCM DTCs that may have been stored during reprogramming. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Seals and Gaskets, CVT > Component Information > Service and Repair > Differential Seals - LH Seals and Gaskets: Service and Repair Differential Seals - LH Differential Seals - LH Special Tools Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Turn the ignition to the OFF position. 3. Remove the retainers and remove the LH splash shield. 4. Remove the drain plug and drain the fluid. 5. Remove the LH halfshaft. 6. Using the Slide Hammer and Input Shaft Oil Seal Remover, remove and discard the LH differential seal. Installation 1. Using the Differential Seal RH and LH installer (two sided tool eCVT) and Handle, install the LH differential seal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Seals and Gaskets, CVT > Component Information > Service and Repair > Differential Seals - LH > Page 3387 2. Install the LH halfshaft. 3. Clean and drain plug threads and apply a small amount of thread sealant on the threads, install the drain plug. ^ Tighten to 40 Nm (30 ft. lbs.). 4. Remove the fill plug on the side of the transaxle. 5. Fill the transaxle with clean automatic transmission fluid as specified until the level reaches the bottom of the fill plug hole. 6. NOTE: Clean the area around the fill plug for transmission fluid that may have spilled on the transaxle case. Install the fill plug. ^ Tighten to 40 Nm (30 ft. lbs.). 7. NOTE: The check and fill plug is located on the left side of the transaxle near the front. NOTE: The transaxle fluid is checked and filled by removing the plug and adding fluid to the bottom of the fill plug hole. Start the engine and check for correct forward and reverse operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Seals and Gaskets, CVT > Component Information > Service and Repair > Differential Seals - LH > Page 3388 Seals and Gaskets: Service and Repair Differential Seals - RH Differential Seals - RH Special Tools Material Removal ALL VEHICLES 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Turn the ignition to the OFF position. 3. Remove the retainers and remove the LH splash shield. 4. Remove the drain plug and drain the transmission fluid. FWD 5. Remove the intermediate shaft. AWD 6. Remove the Power Transfer Unit (PTU). 7. Using the Slide Hammer and RH Halfshaft Fluid Seal Remover, remove and discard the RH differential seal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Seals and Gaskets, CVT > Component Information > Service and Repair > Differential Seals - LH > Page 3389 Installation 1. Using the Differential Seal RH and LH installer (two sided tool eCVT) and Driver 32 Inch Handle, install the RH differential seal. AWD 2. Install the PTU. FWD 3. Install the intermediate shaft. ALL VEHICLES 4. Clean the drain plug threads and apply a small amount of thread sealant on the threads, install the drain plug. ^ Tighten to 40 Nm (30 ft. lbs.). 5. Remove the fill plug on the side of the transaxle. 6. Fill the transaxle with clean automatic transmission fluid as specified until the level reaches the bottom of the fill plug hole. 7. NOTE: Clean the area around the fill plug for transmission fluid that may have spilled on the transaxle case. Install the fill plug. ^ Tighten to 40 Nm (30 ft. lbs.). 8. NOTE: The check and fill plug is located on the left side of the transaxle near the front. NOTE: The transaxle fluid is checked and filled by removing the plug and adding fluid to the bottom of the fill plug hole. Start the engine and check for correct forward and reverse operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Transmission Mode Switch, CVT > Component Information > Diagrams Transmission Mode Switch: Diagrams Electrical Connectors C2096 (Vehicle Harness Side) C2096 (Component Side) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations Transmission Position Switch/Sensor: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 3397 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 3398 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 3399 Transmission Position Switch/Sensor: Description and Operation Transmission Range (TR) Sensor Overview The TR sensor communicates the gear selector position the driver selects to the PCM. The PCM determines a gear mode based on the TR input and the vehicle speed signal. The PCM then broadcasts a gear mode message over the communication link. The TCM uses the gear mode message to engage the transaxle in the gear the driver selected. The other control modules use the gear mode message to control the rear lamps or a brake shift interlock solenoid. The TR sensor is mounted at the base of the gear selector assembly and the sensor shaft is moved by the selector. Transmission Range (TR) Sensor TR Sensor and PCM Interface The TR sensor is a linear potentiometer device that provides the PCM with a percentage of input voltage proportional to the rotational angle of the sensor shaft. The TR sensor consists of: - two independent (TR-A1 and TR-A2) signals - two 5 volt reference (TR-VREF1 and TR-VREF2) lines - two signal return (TR-RTN1 and TR-RTN2) lines The TR-A1 signal has a negative voltage slope, meaning the voltage decreases when the sensor angle increases. The typical TR voltage ranges from approximately 4.3 volts in the PARK position to approximately 0.6 volt in the LOW gear position. The TR-A2 signal has a positive voltage slope. Voltages increase as the sensor angle increases. The typical voltage for the TR-A2 is about 1 volt in the PARK position to about 4.4 volts in the LOW gear position. The TR-VREF circuits are bussed together internal to the TR sensor, and both TR-RTN circuits are bussed together in the TR sensor. One of the TR-VREF and one of the TR-RTN circuits are dedicated signals from the PCM. This design of redundant signals protects against an open circuit condition. Voltage Versus Angle and Gear Selected Chart If the PCM detects a concern in one of TR signal inputs, it uses the other TR signal to determine what gear the driver selects. If the PCM detects one or more TR signals that are invalid, the PCM: - allows the vehicle to travel in DRIVE position or LOW gear position if the vehicle was driving forward at a significant speed when the concern was detected. - allows the vehicle to travel in REVERSE gear if the vehicle was driving backwards at a significant speed when the concern was detected. - broadcasts gear mode - NEUTRAL over the communication link when vehicle speed decreases to 8 km/h (5 mph). - sets the DTC and illuminates the indicator. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Linkage, CVT > Shift Cable, CVT > Component Information > Adjustments Shift Cable: Adjustments Selector Lever Cable Adjustment 1. NOTICE: The ignition must be in the OFF position to make sure that the Electronically Controlled Continuously Variable Transmission (eCVT) and the engine are OFF. With vehicle in NEUTRAL, position it on a hoist. 2. Place the selector lever in the D position. 3. Remove the retainers and the LH splash shield. 4. Remove the 2 bolts and the transaxle selector lever cable splash shield. 5. Remove the selector lever cable end from the manual control lever. 6. Place the manual control lever in DRIVE by positioning the manual control lever between the 2 ribs on the transaxle case. 7. Release the selector lever cable adjuster lock. 1. Pull out on the selector lever cable adjuster lock tabs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Linkage, CVT > Shift Cable, CVT > Component Information > Adjustments > Page 3404 2. Slide the lock over to unlock the selector lever cable. 8. Align the selector lever cable end to the manual control lever ball stud and install it with the selector lever cable adjuster unlocked. 9. Slide the selector lever cable adjuster tab in place to lock the selector lever cable. 10. To verify the correct adjustment, observe the selector lever on the transaxle while an assistant shifts the transmission selector lever to each range position, ending in the D position. 11. Install the transaxle selector lever cable splash shield. - Tighten to 15 Nm (133 lb-in). 12. Install the LH splash shield. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Linkage, CVT > Shift Cable, CVT > Component Information > Adjustments > Page 3405 Shift Cable: Service and Repair Selector Lever Cable Removal and Installation 1. NOTICE: The ignition must be in the OFF position to make sure that the Electronically Controlled Continuously Variable Transmission (eCVT) and the engine are OFF. With vehicle in NEUTRAL, position it on a hoist. 2. Place the selector lever in the D position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Linkage, CVT > Shift Cable, CVT > Component Information > Adjustments > Page 3406 3. Gently pry up to remove the selector lever trim ring. 4. Lift the center console lid and remove the center console compartment tray. 5. Remove the top finish panel from the center console. 6. Disconnect the power outlet electrical connector. 7. Remove the selector lever cable from the selector lever assembly. 1. Disconnect the selector lever cable end from the selector lever. 2. Remove the selector lever cable from the selector lever cable bracket. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Linkage, CVT > Shift Cable, CVT > Component Information > Adjustments > Page 3407 8. Remove the 2 grommet nuts for the selector lever cable. - To install, tighten to 11 Nm (97 lb-in). 9. Remove the selector lever cable retainer from the dash panel. 10. Remove the selector lever cable retainers from the intake manifold and the transaxle. 11. Remove the retainers and the LH splash shield. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Linkage, CVT > Shift Cable, CVT > Component Information > Adjustments > Page 3408 12. Remove the 2 bolts and the transaxle selector lever cable splash shield. - To install, tighten to 15 Nm (133 lb-in). 13. Release the selector lever cable adjuster lock. 1. Pull out on the selector lever cable adjuster lock tabs. 2. Slide the lock over to unlock the selector lever cable. - To install, push the selector lever cable adjuster lock in place to lock the selector lever cable. 14. Remove the selector lever cable end from the manual control lever, remove the selector lever cable bracket nuts and remove the selector lever cable assembly. To install, tighten to 22 Nm (16 lb-ft). 15. NOTE: Before installation, make sure the transmission manual control lever is in the DRIVE position with the ignition in the OFF position or the selector lever cable will have to be adjusted. Place the manual control lever in DRIVE, by positioning the manual control lever between the 2 ribs on the transaxle case. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions Shift Interlock: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3413 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3414 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3415 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3416 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3417 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3418 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3419 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3420 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3421 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3422 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3423 Shift Interlock: 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3424 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3425 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3426 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3427 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3428 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3429 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3430 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3431 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3432 Shift Interlock: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 37-1 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3433 Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Diagrams > Page 3434 Shift Interlock: Service and Repair Brake Shift Interlock Override NOTE: If it is necessary to use the override procedure to move the selector lever out of the PARK position, it is possible that a fuse has blown and the brake lights are not operational. Before driving the vehicle, verify that the brake lights are working. This vehicle is equipped with a brake shift interlock feature that prevents the selector lever from being moved out of PARK when the ignition is in the ON position unless the brake pedal is depressed. If the selector lever cannot be moved out of the PARK position when the ignition is in the ON position and the brake pedal is depressed: 1. Apply the parking brake and remove the ignition key. 2. NOTE: The relief is located at the front of the access panel. Remove the override cap. 3. Using a suitable tool, depress the brake shift interlock override mechanism on the selector lever, apply the brake, depress the button on the selector lever and move the selector lever into NEUTRAL. 4. Start the vehicle. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Service and Repair > Selector Lever Shifter CVT: Service and Repair Selector Lever Selector Lever Removal and Installation NOTE: The Transmission Range (TR) sensor is part of the selector lever assembly. All vehicles 1. Place the selector lever in the D position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Service and Repair > Selector Lever > Page 3440 2. Gently pry up to remove the selector lever trim ring. 3. Lift the center console lid and remove the center console compartment tray. 4. Remove the top finish panel from the center console. 5. Disconnect the power outlet electrical connector. 6. Remove the selector lever cable from the selector lever assembly. 1. Disconnect the selector lever cable end from the selector lever. 2. Remove the selector lever cable from the selector lever bracket. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Service and Repair > Selector Lever > Page 3441 7. Disconnect the TR sensor electrical connector and disconnect the wiring harness fastener from the selector lever. 8. Disconnect the wiring harness retainers from the selector lever. 9. Disconnect the electrical connectors from the selector lever. 1. Disconnect the selector lever electrical connector. 2. Remove the vehicle harness connector from the selector lever. All-Wheel Drive (AWD) vehicles 10. Pull the AWD module straight back and remove it from the back of the selector lever. All vehicles Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Service and Repair > Selector Lever > Page 3442 11. Remove the 2 screws from the center console. 12. Remove the 4 bolts and remove the selector lever assembly. - To install, tighten to 25 Nm (18 lb-ft). 13. To install, reverse the removal procedure. Adjust the selector lever cable. For additional information, refer to Selector Lever Cable Adjustment. See: Shift Linkage/Adjustments Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Service and Repair > Selector Lever > Page 3443 Shifter CVT: Service and Repair Selector Lever Bezel Selector Lever Bezel Removal 1. Place the selector lever in the D position. 2. Gently pry up to remove the selector lever trim ring. 3. Lift the center console lid and remove the center console compartment tray. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Service and Repair > Selector Lever > Page 3444 4. Remove the top finish panel from the center console. 5. Disconnect the power outlet electrical connector. 6. Remove the selector lever knob trim covers by carefully prying out on the bottom front corners and then pry out on the top front corner and remove the covers. 7. Remove the 2 selector lever knob screws and remove the selector lever knob. 8. Remove the selector lever bezel light from the selector lever bezel. 9. NOTE: Selector lever removed for clarity. Release the tabs and remove the selector lever bezel from the selector lever. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Service and Repair > Selector Lever > Page 3445 Installation 1. NOTE: Selector lever removed for clarity. Install the selector lever bezel. Be sure the tabs are correctly fastened on the selector lever. 2. Install the selector lever bezel light in the selector lever bezel. 3. Install the selector lever knob and the 2 screws. 4. Install the selector lever knob trim covers. 5. Connect the power outlet electrical connector. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Service and Repair > Selector Lever > Page 3446 6. Install the center console finish panel. 7. Install the center console compartment tray. 8. Install the selector lever trim ring. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Service and Repair > Selector Lever > Page 3447 Shifter CVT: Service and Repair Selector Lever Knob Selector Lever Knob Removal 1. Remove the selector lever knob trim covers by carefully prying out on the bottom front corners and then pry out on the top front corner and remove the covers. 2. Remove the 2 selector lever knob screws and remove the selector lever knob. Installation 1. Install the selector lever knob and the 2 screws. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Service and Repair > Selector Lever > Page 3448 2. Install the selector lever knob trim covers. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Specifications > Mechanical Specifications Transmission Cooler: Mechanical Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Specifications > Mechanical Specifications > Page 3453 Transmission Cooler: Capacity Specifications Fluid Capacities Motor electronics cooling system......................................................................................................... ........................................................3.5L (3.7 quarts)* * Note: Approximate dry fill capacity Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Specifications > Mechanical Specifications > Page 3454 Transmission Cooler: Fluid Type Specifications Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Specifications > Page 3455 Transmission Cooler: Description and Operation Transaxle Cooling Motor Electronics Cooling System (MECS) The vehicle uses a pump driven cooling system, referred to as the Motor Electronics Cooling System (MECS) pump, to transfer heat generated by the Electronically Controlled Continuously Variable Transmission (eCVT) and the Hybrid Electric Vehicle (HEV) DC/DC converter to the atmosphere. The system uses a coolant-to-air radiator design. The MECS pump is an electric pump that runs any time the ignition is in the ON position. Unlike traditional cooling systems, there is no thermostat in the MECS, so coolant flow should be continuous and considerably less than traditional powertrain cooling systems. The flow direction is from the degas bottle and DC/DC converter to the MECS pump through the eCVT, then through the MECS radiator from the LH to RH side of the vehicle back to the degas bottle. The MECS cooling pump will make an audible noise if it is running and a slight vibration may be felt by touch. Flow can be verified by visually inspecting for coolant flow into the degas bottle. Flow can be viewed easily in the degas bottle by holding a light source behind the degas bottle. Only a portion of the coolant flow is diverted to the degas bottle via the "T" in the coolant outlet hose. Additional flow can be routed to the degas bottle by closing off the flow past the "T" and into the DC/DC converter. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Specifications > Page 3456 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Service and Repair > Procedures Transmission Cooler: Procedures Motor Electronics Cooling System Draining and Filling Special Tool(s) Material Draining CAUTION: The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated, it must be recycled or disposed of correctly. CAUTION: Always refill the motor electronics cooling system (MECS) with the same type of coolant that was drained from the system. Do not mix coolant types. 1. With the vehicle in DRIVE, position it on a hoist. 2. Turn the ignition to the OFF position. 3. Remove the LH splash shield. 4. Place a suitable container below the transaxle. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Service and Repair > Procedures > Page 3459 5. Loosen the hose clamps at the transaxle, then pull the hoses off to allow the coolant to drain. 6. Connect the hoses to the transaxle and install the hose clamps. 7. Install the LH splash shield. Filling and Bleeding with RADKITPLUS 1. Using the special tool, install the RADKITPLUS and follow the manufacturer's instructions to fill and bleed the cooling system. Filling and Bleeding without RADKITPLUS CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle. When adding engine coolant, use a 50/50 mixture of engine coolant and distilled water. To maintain the integrity of the coolant and the cooling system: ^ Vehicle cooling systems are filled with Motorcraft Premium Gold Engine Coolant. Always fill the cooling system with the same coolant that is present in the system. Do not mix coolant types. ^ Do not add/mix orange-colored Motorcraft Specialty Orange Engine Coolant VC-2 or equivalent meeting Ford specification WSS-M97B44-D or green colored Premium Engine Coolant. Mixing coolants may degrade the coolant's corrosion protection. ^ Do not add alcohol, methanol or brine, or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing. ^ Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles originally equipped with Motorcraft Premium Gold Engine Coolant since a Ford-approved recycling process is not yet available. ^ Used engine coolant should be disposed of in an appropriate manner. Follow your communities regulations and standards for recycling and disposing of automotive fluids. 1. CAUTION: Adhesives, stop-leak pellets or small debris in the Motor electronics cooling system (MECS) can cause poor performance or Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Service and Repair > Procedures > Page 3460 temporary blockage of the motor electronics pump. Only use clean, approved coolant when filling the system. Loosen the bleed screw and fill the degas bottle with coolant until it begins to flow out of the bleed hole. Then, close the bleed screw. 2. Turn the ignition to the ON position to actuate the motor electronics cooling pump and continue to fill the degas bottle to the correct level. 3. NOTE: Most of the MECS air bleeding occurs as a normal process at the degas bottle through the vent tube; very little occurs at the bleed screw. To bleed air from the system, loosen the bleed screw and allow air to escape while the M/E coolant pump is operating. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Service and Repair > Procedures > Page 3461 Transmission Cooler: Removal and Replacement Motor Electronics Cooler Motor Electronics Cooler Motor Electronics Cooler 1. Drain the motor electronics cooling system (MECS). For additional information, refer to Motor Electronics Cooling System Draining and Filling. See: Service and Repair/Procedures 2. Remove the front bumper cover. 3. Loosen the hose clamp and disconnect the MECS radiator inlet hose. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Service and Repair > Procedures > Page 3462 4. Loosen the hose clamp and disconnect the MECS radiator outlet hose. 5. NOTE: RH shown, LH similar. Remove the MECS radiator bolts. ^ To install, tighten to 6 Nm (53 lb-in). 6. To install, reverse the removal procedure. Motor Electronics Pump Motor Electronics Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Service and Repair > Procedures > Page 3463 1. Drain the motor electronics cooling system (MECS). For additional information, refer to See: Service and Repair/Procedures 2. Disconnect the inlet and outlet hoses. ^ Disconnect the harness connector. 3. Remove the bolts. ^ To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Service and Repair > Page 3464 Transmission Cooler: Tools and Equipment Transaxle Cooling Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Mode Switch, CVT > Component Information > Diagrams Transmission Mode Switch: Diagrams Electrical Connectors C2096 (Vehicle Harness Side) C2096 (Component Side) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Mount, CVT > Component Information > Diagrams > Transmission Insulator and Retainer - Upper Transmission Mount: Diagrams Transmission Insulator and Retainer - Upper Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Mount, CVT > Component Information > Diagrams > Transmission Insulator and Retainer - Upper > Page 3472 Transmission Mount: Diagrams Transmission Insulator and Retainer - Rear Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Mount, CVT > Component Information > Diagrams > Transmission Insulator and Retainer - Upper > Page 3473 Transmission Mount: Diagrams Transmission Insulator and Retainer - Lower Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Mount, CVT > Component Information > Service and Repair > Transmission Insulator and Retainer - Lower Transmission Mount: Service and Repair Transmission Insulator and Retainer - Lower Transmission Insulator and Retainer - Lower Removal and Installation Transmission Insulator and Retainer - Lower 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Turn the ignition to the OFF position. 3. Remove the splash shield retainers and remove the LH splash shield. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Mount, CVT > Component Information > Service and Repair > Transmission Insulator and Retainer - Lower > Page 3476 4. Remove the bolts and the lateral support crossmember. - To install, tighten to 115 Nm (85 lb-ft). 5. Remove the lower insulator through bolt. - To install, tighten to 115 Nm (85 lb-ft). 6. Remove the rear roll restrictor-to-crossmember through bolt. - To install, tighten to 90 Nm (66 lb-ft). 7. Remove and discard the engine support crossmember nut. Remove the 2 engine support crossmember bolts. - To install, tighten the new engine support crossmember nut to 175 Nm (129 lb-ft). - To install, tighten the 2 engine support crossmember bolts to 90 Nm (66 lb-ft). 8. Remove the engine support crossmember. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Mount, CVT > Component Information > Service and Repair > Transmission Insulator and Retainer - Lower > Page 3477 9. Remove the rear roll restrictor through bolt and remove the rear roll restrictor from the bracket. - To install, tighten to 90 Nm (66 lb-ft). 10. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Mount, CVT > Component Information > Service and Repair > Transmission Insulator and Retainer - Lower > Page 3478 Transmission Mount: Service and Repair Transmission Insulator and Retainer - Rear Transmission Insulator and Retainer - Rear Transmission Insulator and Retainer - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the rear insulator through bolt. - To install, tighten to 115 Nm (85 lb-ft). 3. Remove the rear insulator nuts and bolt. - To install, tighten to 80 Nm (59 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Mount, CVT > Component Information > Service and Repair > Transmission Insulator and Retainer - Lower > Page 3479 4. Remove the rear insulator studs. - To install, tighten to 12 Nm (106 lb-in). 5. Remove the rear insulator. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Mount, CVT > Component Information > Service and Repair > Transmission Insulator and Retainer - Lower > Page 3480 Transmission Mount: Service and Repair Transmission Insulator and Retainer - Upper Transmission Insulator and Retainer - Upper Transmission Insulator and Retainer - Upper Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Mount, CVT > Component Information > Service and Repair > Transmission Insulator and Retainer - Lower > Page 3481 Removal and Installation 1. Remove the Air Cleaner (ACL) assembly. 2. Install the Engine Support Bar, Support Leg Adapter, Engine Support Bar Adapter and Lifting Hook Adapter. 3. Remove the upper insulator bracket bolts and the bracket. - To install, tighten to 25 Nm (18 lb-ft). 4. Remove the upper insulator. 1. Remove the upper insulator nuts. - To install, tighten to 90 Nm (66 lb-ft). 2. Remove the upper insulator through bolt. - To install, tighten the bolt to 103 Nm (76 lb-ft). 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations Transmission Position Switch/Sensor: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 3485 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 3486 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 3487 Transmission Position Switch/Sensor: Description and Operation Transmission Range (TR) Sensor Overview The TR sensor communicates the gear selector position the driver selects to the PCM. The PCM determines a gear mode based on the TR input and the vehicle speed signal. The PCM then broadcasts a gear mode message over the communication link. The TCM uses the gear mode message to engage the transaxle in the gear the driver selected. The other control modules use the gear mode message to control the rear lamps or a brake shift interlock solenoid. The TR sensor is mounted at the base of the gear selector assembly and the sensor shaft is moved by the selector. Transmission Range (TR) Sensor TR Sensor and PCM Interface The TR sensor is a linear potentiometer device that provides the PCM with a percentage of input voltage proportional to the rotational angle of the sensor shaft. The TR sensor consists of: - two independent (TR-A1 and TR-A2) signals - two 5 volt reference (TR-VREF1 and TR-VREF2) lines - two signal return (TR-RTN1 and TR-RTN2) lines The TR-A1 signal has a negative voltage slope, meaning the voltage decreases when the sensor angle increases. The typical TR voltage ranges from approximately 4.3 volts in the PARK position to approximately 0.6 volt in the LOW gear position. The TR-A2 signal has a positive voltage slope. Voltages increase as the sensor angle increases. The typical voltage for the TR-A2 is about 1 volt in the PARK position to about 4.4 volts in the LOW gear position. The TR-VREF circuits are bussed together internal to the TR sensor, and both TR-RTN circuits are bussed together in the TR sensor. One of the TR-VREF and one of the TR-RTN circuits are dedicated signals from the PCM. This design of redundant signals protects against an open circuit condition. Voltage Versus Angle and Gear Selected Chart If the PCM detects a concern in one of TR signal inputs, it uses the other TR signal to determine what gear the driver selects. If the PCM detects one or more TR signals that are invalid, the PCM: - allows the vehicle to travel in DRIVE position or LOW gear position if the vehicle was driving forward at a significant speed when the concern was detected. - allows the vehicle to travel in REVERSE gear if the vehicle was driving backwards at a significant speed when the concern was detected. - broadcasts gear mode - NEUTRAL over the communication link when vehicle speed decreases to 8 km/h (5 mph). - sets the DTC and illuminates the indicator. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair Differential Cover: Service and Repair Differential Housing Cover Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 10 bolts and the rear differential cover. - Drain the differential fluid from the housing. Installation 1. NOTE: Make sure the machined surfaces on the rear axle housing and the differential housing cover 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 and the differential housing cover. 2. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has correctly cured. Apply a new continuous bead of clear silicone rubber as shown in the illustration. 3. Install the differential housing cover and the 10 bolts. - Tighten to 23 Nm (17 lb-ft). 4. Fill the rear axle with 1.15L (2.43 pt) of rear axle lubricant, 3-5mm (0.118-0.196 in) below the bottom of the filler hole and install the filler plug. - Tighten to 27 Nm (20 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Rear Axle ............................................................................................................................................. .................................................. 2.96 pints (1.4 liters) NOTE: Fill to 1/4 inch to 9/16 inch (6 mm to 14 mm) below bottom of fill hole. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 3496 Fluid - Differential: Fluid Type Specifications Differential Fluid Type REAR AXLE Motorcraft SAE 80W-90 Premium Rear Axle Lubricant Ford P/N .................................. .............................................................................................................................................................. ....... XY-80W90-QL Ford Specification ............................................................................................... ....................................................................................... WSP-M2C197-A NOTE: Vehicles exposed for prolonged periods to temperatures less than 40 Celsius (-40 Fahrenheit) should change out the rear axle fluid to Motorcraft SAE 75W-140 High Performance Rear Axle Lubricant, Ford part number XY-75W140-QL meeting Ford specification WSL-M2C192-A. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Stub Shaft Seal Seals and Gaskets: Service and Repair Stub Shaft Seal Stub Shaft Seal Removal 1. NOTE: There is no bearing for the stud shaft. There is a seal only. Remove the halfshaft assembly. 2. Use the Torque Converter Fluid Seal Remover and Slide Hammer to remove the stub shaft seal. Installation 1. NOTE: Lubricate the new stub shaft seal with grease. Using the Front Axle Oil Seal Installer and Handle, install the stub shaft seal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Stub Shaft Seal > Page 3501 2. NOTE: Inspect the inboard CV joint seal journal for rust or nicks/scratches prior to installing the halfshaft. If necessary, polish the seal journal with fine crocus cloth. Install the halfshaft assembly. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Stub Shaft Seal > Page 3502 Seals and Gaskets: Service and Repair Drive Pinion Seal Drive Pinion Seal Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Index-mark the driveshaft flange and the pinion flange. 3. NOTE: Support the driveshaft. Disconnect the rear driveshaft U-joint flange. - Remove and discard the 4 bolts. - Position aside the driveshaft and flange. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Stub Shaft Seal > Page 3503 4. Using the Drive Pinion Flange Holding Fixture, hold the pinion flange while removing the nut. - Remove and discard the pinion flange nut. 5. Index-mark the location of the pinion to the flange. 6. Using the 2-Jaw Puller, remove the pinion flange. 7. Using the Converter Seal Remover and Slide Hammer, remove the pinion seal. Installation 1. NOTE: Make sure that the mating surface is clean before installing the new seal. Using the Pinion Drive Seal Installer, install the pinion seal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Stub Shaft Seal > Page 3504 2. NOTE: Lubricate the pinion flange with grease. Line up the index marks and position the pinion flange. 3. Using the Drive Pinion Flange Holding Fixture, install a new pinion nut. - Tighten to 244 Nm (180 lb-ft). 4. Line up the index marks and position the rear driveshaft and U-joint flange. - Install the 4 new bolts. - Tighten to 70 Nm (52 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Front Drive Halfshafts Axle Shaft Assembly: Specifications Front Drive Halfshafts Material Torque Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Front Drive Halfshafts > Page 3510 Axle Shaft Assembly: Specifications Rear Drive Halfshafts Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Description and Operation > Front Drive Halfshafts Axle Shaft Assembly: Description and Operation Front Drive Halfshafts Front Drive Halfshafts The halfshafts and intermediate shaft consists of the following components: - Inner CV joints - Outer CV joints - A support bearing on the intermediate shaft The shafts are serviced as assemblies only. The front drive halfshafts are splined to drive the front wheel hubs. The LH halfshaft uses a circlip to retain the inner CV joint stub shaft in the differential side gear. The RH halfshaft is connected to an intermediate shaft with a circlip. The intermediate shaft is also driven by a differential side gear. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Description and Operation > Front Drive Halfshafts > Page 3513 Axle Shaft Assembly: Description and Operation Rear Drive Halfshafts Rear Drive Halfshafts The rear drive halfshafts have the following features: - The inner and outer CV joints connect to a splined shaft. A circlip stopper holds the cross groove inner race assembly (inner CV joint) together. - The RH and LH halfshafts are the same length. - An axle circlip retains the splined inner CV joint to the differential side gear. - A rear axle wheel hub nut secures the side shaft assembly (interconnecting shaft and outer CV joint) to the rear hub. - The rear halfshafts are serviced as assemblies only. The rear drive halfshafts are driven by the differential side gears in the rear drive axle. The splined inner CV joint housing transfers the torque to the connecting shaft through the flexible joint consisting of caged balls or 3 roller trunion. This allows the connecting shaft to change both length and angle while the joint housing remains fixed. The CV joints are lubricated with a special high temperature grease that is contained by flexible rubber boots sealed to the joint housing and connecting shafts by clamps. The outer CV joint receives the rotational force from the connecting shaft and in turn, drives the rear wheel hub. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Description and Operation > Front Drive Halfshafts > Page 3514 Axle Shaft Assembly: Description and Operation Halfshaft Joint Halfshaft Joint The front drive halfshaft CV joints consist of the following components: - Inner CV joints - Outer CV joints - CV joint boot clamps - Convoluted CV joint boots - Tripod joint housings - Ball and cage housings - Retainer circlips - Special CV high temperature grease The halfshaft joint allows for smooth rotation of the interconnecting shaft and the outboard housing. It also adjusts for length requirements as the vehicle goes through jounce and rebound. The halfshaft joints are not repairable and are serviced as assemblies only. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Front Drive Halfshafts Axle Shaft Assembly: Service and Repair Front Drive Halfshafts Halfshaft Halfshaft NOTE: RH halfshaft shown, LH similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Front Drive Halfshafts > Page 3517 Removal All halfshafts 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the wheel and tire. 3. Remove and discard the wheel hub nut. 4. Remove the ABS wheel speed sensor bolt and position the sensor aside. 5. Remove the lower ball joint bolt and nut. - Discard the nut and bolt. 6. NOTE: Do not allow the ball joint stud to contact the CV joint boot. Separate the lower arm from the front wheel knuckle. 7. Using the Front Hub Remover, separate the halfshaft from the wheel hub. Left halfshaft 8. Using the Halfshaft Remover and Slide Hammer, remove the LH halfshaft from the differential. Right halfshaft 9. Using a brass drift to strike the RH halfshaft in the indicated area, separate and remove the halfshaft. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Front Drive Halfshafts > Page 3518 Installation Left halfshaft 1. NOTE: When seated correctly, the halfshaft bearing retainer circlip can be felt as it snaps into the differential side gear groove. Position the LH halfshaft so the splines line up with the differential side gear splines. Push the halfshaft into the differential side gear. Right halfshaft 2. Align the RH halfshaft with the splines of the intermediate shaft and push the halfshaft in until the circlip locks the shafts together. - Apply a thin coat of the specified grease to the splines of the intermediate shaft. All halfshafts 3. Using the Halfshaft Installer, install the halfshaft into the front wheel hub. 4. Position the lower arm into the front wheel knuckle. 5. Install the new lower ball joint bolt and nut. - Tighten to 63 Nm (46 lb-ft). 6. Install the ABS wheel speed sensor and bolt. - Tighten to 9 Nm (80 lb-in). 7. NOTICE: Do not tighten the front wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied. NOTE: Apply the brake to keep the halfshaft from rotating. Install new front wheel hub nut. - Tighten to 300 Nm (222 lb-ft). 8. Install the front tires and wheels. 9. Check and fill the transaxle fluid as necessary. Intermediate Shaft Intermediate Shaft Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Front Drive Halfshafts > Page 3519 Removal and Installation 1. NOTE: If removing the intermediate shaft in order to repair a separate component, it should only be removed as an assembly with the RH front drive halfshaft. Remove the RH halfshaft. For additional information, refer to Halfshaft See: Halfshaft. 2. Remove the 2 intermediate shaft bearing retainer nuts. - To install, tighten to 27 Nm (20 lb-ft). 3. Remove the intermediate shaft. 4. NOTICE: On All-Wheel Drive (AWD) vehicles, the Power Transfer Unit (PTU) seal must be replaced everytime the intermediate shaft is removed. To install, reverse the removal procedure. Apply a thin coat of the specified grease to the splines of the intermediate shaft. 5. Check and fill the transaxle fluid as necessary. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Front Drive Halfshafts > Page 3520 Axle Shaft Assembly: Service and Repair Rear Drive Halfshafts Halfshaft Halfshaft Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Front Drive Halfshafts > Page 3521 Removal NOTICE: Never pick up or hold the halfshaft by only the inner or outer Constant Velocity (CV) joint. Damage to the CV joint will occur. NOTICE: Never use a hammer to remove or install the halfshafts. Damage to the halfshaft may occur. NOTICE: Never use the halfshaft assembly as a lever to position other components. Damage to the halfshaft or Constant Velocity (CV) joints may occur. NOTICE: Do not allow the boots to contact sharp edges or hot exhaust components. Damage to the halfshaft boots will occur. NOTICE: Do not drop assembled halfshafts. The impact may cut the boots from the inside without evidence of external damage. 1. Remove the coil spring. 2. Remove and discard the wheel hub nut. 3. Remove the wheel speed sensor harness-to-body bolt. 4. Remove and discard the 4 stabilizer bar bracket upper and lower bolts. 5. NOTE: Support the wheel knuckle. Remove the nut and separate the lower ball joint. 6. NOTICE: Do not damage the oil seal when removing the axle halfshaft from the differential. NOTE: Support the halfshaft inner joint. Using the Halfshaft Remover Tool, remove the halfshaft from the differential. 7. Using the Front Hub Remover, separate the halfshaft from the rear wheel hub assembly. - Remove the halfshaft. Installation 1. Using the Halfshaft Installer, install the outer halfshaft end into the hub assembly. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Front Drive Halfshafts > Page 3522 2. Using the Axle Seal Protector, install the halfshaft into the differential. 3. If the axle is equipped with the oil seal protector, make sure the oil seal lip and seal protector are correctly aligned. 4. Position the lower ball joint and install the lower ball joint nut. - To install, tighten to 63 Nm (46 lb-ft). 5. Install the rear coil spring. 6. Install the 4 new stabilizer bar bracket upper and lower bolts. - Tighten the lower bolts to 115 Nm (85 lb-ft). - Tighten the upper bolts to 90 Nm (66 lb-ft). 7. Install the wheel speed sensor harness-to-body bolt. - Tighten to 9 Nm (80 lb-in). 8. NOTICE: Do not tighten the rear wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied. NOTE: Apply the brake to keep the halfshaft from rotating. Install the wheel hub nut. - To install, tighten to 300 Nm (221 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Wheel Bearing and Wheel Hub Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. NOTE: If removing the wheel hub, a new wheel bearing must be installed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 3527 1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair. 2. Using the Pinion Bearing Cone Remover, press the wheel hub from the wheel bearing. 3. 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 Pinion Bearing Cone Remover, press the inner wheel bearing race from the wheel hub. 4. Remove the snap ring. 5. Using the Pinion Bearing Cone Remover, Wheel Bearing Adapter and Handle, press the outer wheel bearing race from the wheel knuckle. Installation 1. Position the wheel knuckle in a vise. 2. NOTE: Step Plate 205-278 is not seen in place. It is located behind the wheel knuckle. Using the Pinion Bearing Cup Replacer and the 2 Step Plates, install the wheel bearing into the wheel knuckle. 3. Install the snap ring. 4. Using the Pinion Bearing Cone Remover, press the wheel hub into the wheel bearing. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 3528 5. Install the wheel knuckle. For additional information, refer to Wheel Knuckle See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 3529 Wheel Bearing: Service and Repair Rear Suspension Wheel Bearing - All Wheel Drive (AWD) Removal Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 3530 1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle - All Wheel Drive (AWD) See: Steering and Suspension/Suspension/Rear Knuckle/Service and Repair. 2. Remove the wheel bearing snap ring. 3. Remove the 4 bolts and the brake drum backing plate. 4. Position the wheel knuckle on a suitable press. - Using the PTO Driven Gear Oil Seal Installer, the Handle and the Pinion Bearing Cone Remover or equivalent, position the wheel knuckle on a suitable press and press the wheel bearing from the wheel knuckle. Installation 1. Using the Rear Axle Drawbar, Bearing Cup Replacer and Differential Bearing Cup Replacer, install a new wheel bearing into the wheel knuckle. 2. Install the new wheel bearing snap ring. 3. Install the 4 bolts and the brake drum backing plate. - Tighten to 85 Nm (63 lb-ft). 4. Using the Halfshaft Installer and Receiver Adapter, install the wheel hub into the wheel bearing. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 3531 5. Install the wheel knuckle. For additional information, refer to Wheel Knuckle - All Wheel Drive (AWD) See: Steering and Suspension/Suspension/Rear Knuckle/Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Rear Install the new wheel hub nut Tighten to..................................................................................... ..............................................................................................................290 Nm (214 lb-ft). Front Install the new wheel hub nut Tighten to..................................................................................... ..............................................................................................................300 Nm (221 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > Customer Interest for Center Support: > 11-2-19 > Feb > 11 > Drivetrain/Exhaust - Highway Speed Rumble/Vibration Center Support: Customer Interest Drivetrain/Exhaust - Highway Speed Rumble/Vibration TSB 11-2-19 02/28/11 AWD - COLD TEMPERATURES - VIBRATION AT HIGHWAY SPEEDS AND/OR VIBRATION/RUMBLE/EXCESSIVE EXHAUST NOISE AFTER A COLD START - BUILT ON OR BEFORE 6/13/2010 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 10-16-2 to add a production fix date, update the Issue Statement Service Procedure and Part List. ISSUE Some 2009-2010 Escape and Mariner AWD vehicles built on or before 6/13/2010 may exhibit a highway speed vibration that is isolated to the rear driveshaft and/or a vibration/rumble/excessive exhaust type noise when in ambient temperatures of approximately -26 degrees Celsius (-15 degrees Fahrenheit) or lower. The vibration and/or noise will eventually diminish once vehicle reaches normal operating temperature. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE Vehicles exhibiting a vibration/rumble/excessive exhaust type noise, proceed to Step 1. For vehicles with a highway speed driveshaft vibration only, skip to Step 2. 1. Replace all five (5) exhaust hangers. Refer to WSM, Section 309-00. 2. Replace the rear driveshaft center bearing assembly. Refer to Instruction Sheet included in the kit, and Workshop Manual (WSM), Section 205-01. Parts Block 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 110219A 2009-2010 Escape And 0.3 Hr. Mariner AWD: Replace All Five (5) Exhaust Hangers (Do Not Use With Any Other Labor Operations) 110219B 2009-2010 Escape And 1.0 Hr. Mariner AWD: Replace The Rear Driveshaft Center Bearing Assembly (Do Not Use With Any Other Labor Operations) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > Customer Interest for Center Support: > 11-2-19 > Feb > 11 > Drivetrain/Exhaust - Highway Speed Rumble/Vibration > Page 3545 110219C 2009-2010 Escape And 1.1 Hrs. Mariner AWD: Replace The Rear Driveshaft Center Bearing Assembly And Replace All Five (5) Exhaust Hangers (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 4R602 D4 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Support: > 11-2-19 > Feb > 11 > Drivetrain/Exhaust - Highway Speed Rumble/Vibration Center Support: All Technical Service Bulletins Drivetrain/Exhaust - Highway Speed Rumble/Vibration TSB 11-2-19 02/28/11 AWD - COLD TEMPERATURES - VIBRATION AT HIGHWAY SPEEDS AND/OR VIBRATION/RUMBLE/EXCESSIVE EXHAUST NOISE AFTER A COLD START - BUILT ON OR BEFORE 6/13/2010 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 10-16-2 to add a production fix date, update the Issue Statement Service Procedure and Part List. ISSUE Some 2009-2010 Escape and Mariner AWD vehicles built on or before 6/13/2010 may exhibit a highway speed vibration that is isolated to the rear driveshaft and/or a vibration/rumble/excessive exhaust type noise when in ambient temperatures of approximately -26 degrees Celsius (-15 degrees Fahrenheit) or lower. The vibration and/or noise will eventually diminish once vehicle reaches normal operating temperature. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE Vehicles exhibiting a vibration/rumble/excessive exhaust type noise, proceed to Step 1. For vehicles with a highway speed driveshaft vibration only, skip to Step 2. 1. Replace all five (5) exhaust hangers. Refer to WSM, Section 309-00. 2. Replace the rear driveshaft center bearing assembly. Refer to Instruction Sheet included in the kit, and Workshop Manual (WSM), Section 205-01. Parts Block 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 110219A 2009-2010 Escape And 0.3 Hr. Mariner AWD: Replace All Five (5) Exhaust Hangers (Do Not Use With Any Other Labor Operations) 110219B 2009-2010 Escape And 1.0 Hr. Mariner AWD: Replace The Rear Driveshaft Center Bearing Assembly (Do Not Use With Any Other Labor Operations) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Support: > 11-2-19 > Feb > 11 > Drivetrain/Exhaust - Highway Speed Rumble/Vibration > Page 3551 110219C 2009-2010 Escape And 1.1 Hrs. Mariner AWD: Replace The Rear Driveshaft Center Bearing Assembly And Replace All Five (5) Exhaust Hangers (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 4R602 D4 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 11-2-19 > Feb > 11 > Drivetrain/Exhaust - Highway Speed Rumble/Vibration Drive/Propeller Shaft: Customer Interest Drivetrain/Exhaust - Highway Speed Rumble/Vibration TSB 11-2-19 02/28/11 AWD - COLD TEMPERATURES - VIBRATION AT HIGHWAY SPEEDS AND/OR VIBRATION/RUMBLE/EXCESSIVE EXHAUST NOISE AFTER A COLD START - BUILT ON OR BEFORE 6/13/2010 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 10-16-2 to add a production fix date, update the Issue Statement Service Procedure and Part List. ISSUE Some 2009-2010 Escape and Mariner AWD vehicles built on or before 6/13/2010 may exhibit a highway speed vibration that is isolated to the rear driveshaft and/or a vibration/rumble/excessive exhaust type noise when in ambient temperatures of approximately -26 degrees Celsius (-15 degrees Fahrenheit) or lower. The vibration and/or noise will eventually diminish once vehicle reaches normal operating temperature. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE Vehicles exhibiting a vibration/rumble/excessive exhaust type noise, proceed to Step 1. For vehicles with a highway speed driveshaft vibration only, skip to Step 2. 1. Replace all five (5) exhaust hangers. Refer to WSM, Section 309-00. 2. Replace the rear driveshaft center bearing assembly. Refer to Instruction Sheet included in the kit, and Workshop Manual (WSM), Section 205-01. Parts Block 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 110219A 2009-2010 Escape And 0.3 Hr. Mariner AWD: Replace All Five (5) Exhaust Hangers (Do Not Use With Any Other Labor Operations) 110219B 2009-2010 Escape And 1.0 Hr. Mariner AWD: Replace The Rear Driveshaft Center Bearing Assembly (Do Not Use With Any Other Labor Operations) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 11-2-19 > Feb > 11 > Drivetrain/Exhaust - Highway Speed Rumble/Vibration > Page 3560 110219C 2009-2010 Escape And 1.1 Hrs. Mariner AWD: Replace The Rear Driveshaft Center Bearing Assembly And Replace All Five (5) Exhaust Hangers (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 4R602 D4 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 11-2-19 > Feb > 11 > Drivetrain/Exhaust - Highway Speed Rumble/Vibration Drive/Propeller Shaft: All Technical Service Bulletins Drivetrain/Exhaust - Highway Speed Rumble/Vibration TSB 11-2-19 02/28/11 AWD - COLD TEMPERATURES - VIBRATION AT HIGHWAY SPEEDS AND/OR VIBRATION/RUMBLE/EXCESSIVE EXHAUST NOISE AFTER A COLD START - BUILT ON OR BEFORE 6/13/2010 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 10-16-2 to add a production fix date, update the Issue Statement Service Procedure and Part List. ISSUE Some 2009-2010 Escape and Mariner AWD vehicles built on or before 6/13/2010 may exhibit a highway speed vibration that is isolated to the rear driveshaft and/or a vibration/rumble/excessive exhaust type noise when in ambient temperatures of approximately -26 degrees Celsius (-15 degrees Fahrenheit) or lower. The vibration and/or noise will eventually diminish once vehicle reaches normal operating temperature. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE Vehicles exhibiting a vibration/rumble/excessive exhaust type noise, proceed to Step 1. For vehicles with a highway speed driveshaft vibration only, skip to Step 2. 1. Replace all five (5) exhaust hangers. Refer to WSM, Section 309-00. 2. Replace the rear driveshaft center bearing assembly. Refer to Instruction Sheet included in the kit, and Workshop Manual (WSM), Section 205-01. Parts Block 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 110219A 2009-2010 Escape And 0.3 Hr. Mariner AWD: Replace All Five (5) Exhaust Hangers (Do Not Use With Any Other Labor Operations) 110219B 2009-2010 Escape And 1.0 Hr. Mariner AWD: Replace The Rear Driveshaft Center Bearing Assembly (Do Not Use With Any Other Labor Operations) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 11-2-19 > Feb > 11 > Drivetrain/Exhaust - Highway Speed Rumble/Vibration > Page 3566 110219C 2009-2010 Escape And 1.1 Hrs. Mariner AWD: Replace The Rear Driveshaft Center Bearing Assembly And Replace All Five (5) Exhaust Hangers (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 4R602 D4 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 3567 Drive/Propeller Shaft: Description and Operation Driveshaft NOTICE: All driveshaft assemblies are balanced. If undercoating the vehicle, protect the driveshaft to prevent overspray of any undercoating material or an unbalanced condition may occur. The driveshaft consists of: - spot-welded balance weights. - a front CV joint at the Power Transfer Unit (PTU). - a center support bearing assembly with a ground strap. - staked and snap ring type U-joints. - U-joint cap straps for the center U-joint. - square flanged rear U-joint. The driveshaft is a 2-piece shaft which transfers the rotational torque from the PTU to the rear drive axle. The driveshaft uses CV joints, U-joints and a center support for consistent operation through varying lengths and angles. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures Drive/Propeller Shaft: Procedures Driveline Angle Measurement Driveline Angle Measurement NOTE: This procedure does not apply to CV joints, flex couplers or double cardan joints that are used in some driveshafts. This check is for single-cross and roller-style joints found in the driveshafts. NOTE: Prior to checking driveline angularity, inspect the U-joints for correct operation. NOTE: An incorrect driveline angle can cause a vibration or shudder. NOTE: Driveline angularity is the angular relationship between the engine crankshaft, the driveshaft and the rear axle pinion. Factors determining driveline angularity include ride height, rear spring and engine mounts. All vehicles 1. Carry out the following preliminary setup steps: - Inspect the U-joints for correct operation. - Park the vehicle on a level surface such as a drive-on hoist, or back onto a front end alignment rack. - Verify the curb position ride height is within specifications with the vehicle unloaded and all of the tires are inflated to their normal operating pressures. - Calibrate the Anglemaster II Driveline Inclinometer/Protractor by placing it on a clean, flat level section of the frame rail and press the ALT-ZERO button. Vehicles with flat-flanged, split-pin or slip-flanged U-joints 2. NOTE: If equipped, remove the snap ring to allow access to the base of the U-joint cup. Make sure the Anglemaster II Driveline Inclinometer/Protractor is seated against the U-joint cup. NOTE: Rotate the driveshaft until the flange U-joint cup is parallel with the floor. This will simplify taking measurements. To check the U-joint operating angle, install the Anglemaster II Driveline Inclinometer/Protractor. Check and record the flange angle as angle A. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 3570 3. Using the Anglemaster II Driveline Inclinometer/Protractor, measure the slope of the connecting component. Record the measurement of the component angle as angle B. Multiple piece driveshafts 4. NOTE: Repeat this step for each center support bearing on the driveshaft. NOTE: It is not necessary to remove the U-joint snap ring, if equipped, for these measurements. Using the Anglemaster II Driveline Inclinometer/Protractor, measure the slope of the components in front and behind the center support bearing U-joint in the area indicated. Record the front component as angle A and the rear component as angle B. All vehicles 5. NOTE: When 2 connected components slope in the same direction, subtract the smallest number from the larger number to find the U-joint operating angle. When 2 connected components slope in the opposite direction, add the measurements to find the U-joint operating angle. Calculate the difference in the slope of the components to determine the U-joint operating angle. - The U-joint operating angle is the angle formed by 2 yokes connected by a cross and bearing kit. Ideally, the operating angles on each connection of the driveshaft must: be equal or within one degree of each other. - have a 3 degree maximum operating angle. - have at least one-half of one degree continuous operating angle. 6. If the angle is not within specifications, repair or adjust to obtain the correct angle. Inspect the engine mounts, transmission mounts, center support bearing mounting, rear suspension, rear axle, rear axle mounting or the frame for wear or damage. Driveshaft Runout And Balancing Driveshaft Runout and Balancing Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 3571 Driveshaft Inspection NOTE: Driveline vibration exhibits a higher frequency and lower amplitude than high-speed shake. Driveline vibration is directly related to the speed of the vehicle and is noticed at various speeds. Driveline vibration can be perceived as a tremor in the floorpan or heard as a rumble, hum or boom. NOTE: Refer to Specifications for all runout specifications. 1. NOTE: Do not make any adjustments before carrying out a road test. Do not change the tire pressure or the vehicle load. Carry out a visual inspection of the vehicle. Operate the vehicle and verify the condition by reproducing it during the road test. - The concern should be directly related to vehicle road speed, not affected by acceleration or deceleration or could not be reduced by coasting in NEUTRAL. 2. With the vehicle in NEUTRAL, position it on a hoist. - The driveshaft should be kept at an angle equal to or close to the curb-weighted position. Use a twin-post hoist or a frame hoist with jackstands. 3. Inspect the driveshaft for damage, undercoating or incorrectly seated U-joints. Rotate the driveshaft slowly by hand and feel for binding or end play in the U-joint trunnions. Remove the driveshaft. Inspect the slip yoke splines for any galling, dirt, rust or incorrect lubrication. Clean the driveshaft or install new U-joints as necessary. Install a new driveshaft if damaged. After any corrections or new components are installed, recheck for the vibration at the road test speed. If the vibration is gone, test drive the vehicle. - If the vibration persists or the driveshaft passes visual inspection, measure the driveshaft runout. Driveshaft Runout 1. Install the Dial Indicator Gauge with Holding Fixture. Rotate the driveshaft by turning the axle and measure the runout at the front, the center and the rear of the driveshaft. If the runout exceeds 1 mm (0.040 in) at the front or center, install a new driveshaft. - If the front and center is within 1 mm (0.040 in), but the rear runout is not, index-mark the rear runout high point and proceed to Step 2. - If the runout is within 1 mm (0.040 in) at all points, recheck for vibration at road test speed. If the vibration persists, balance the driveshaft. For additional information, refer to Driveshaft Balancing in this procedure. 2. NOTE: Circular pinion flanges can be turned in 90 degree or one-fourth increments. Half-round pinion flanges are limited to 2 positions. Index-mark the driveshaft to the pinion flange. Disconnect the driveshaft and rotate it 180 degrees. Reconnect the driveshaft. Recheck the runout at the rear of the driveshaft. - If the runout is still over specification, mark the high point and proceed to Step 3. - If the runout is within specification, check for the vibration at the road test speed. If the vibration is still present, balance the driveshaft. For additional information, refer to Driveshaft Balancing in this procedure. 3. Excessive driveshaft runout can originate in the driveshaft itself or from the pinion flange. To find the source, compare the 2 high points previously determined. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 3572 - If the index marks are close together, within 25 mm (1 in), the driveshaft is eccentric. Install a new driveshaft. - If the marks are on opposite sides of the driveshaft, 180 degrees apart, the slip yoke or pinion flange is responsible. Check the pinion flange runout. If the pinion flange runout exceeds specifications, a bent pinion is indicated. - If the pinion flange and pinion runouts are within specifications, road test and check for the vibration at the road test speed. If the vibration persists, balance the driveshaft. For additional information, refer to Driveshaft Balancing in this procedure. Driveshaft Balancing - Using the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix) All vehicles 1. Install the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix) to the vehicle. 2. Working under the vehicle, install an accelerometer. The accelerometer can be attached and mounted near either the transmission or differential end of the driveshaft. 3. Clean an area of the driveshaft and install the reflective tape, then install the photo-tachometer sensor. The sensor should be placed at approximately a 20-degree angle from perpendicular to the surface of the reflective tape. Make sure the sensor does not get moved during the balance procedure. 1. Reflective tape. 2. Photo-tachometer sensor. 4. Using the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run a driveshaft balance test with the driveshaft unmodified. Vehicles with tapped pinion flanges 5. Label the tapped holes in the pinion flange numerically, starting at the top hole as 1. Mark the remaining holes 2, 3 and 4. Label in the direction of rotation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 3573 6. Using the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run a second test with the 12 mm (0.47 in) test weight set screw in the No. 1 hole, previously marked on the pinion flange. 7. Remove the test weight, then install the weight combination directed by the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix). Vehicles without tapped pinion flanges 8. Using the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run a second test with a test weight. Using a metal band, secure the test weight to the end of the driveshaft. The weight should be placed at the end of the driveshaft tube, as close to the tube-to-yoke weld seam as possible. Mark the location of the test weight on the driveshaft, as shown in the figure below. 1. Test weight. 2. Tube-to-yoke weld seam. 3. Driveshaft pinion flange. - Select the test weight based on driveshaft size. Larger driveshafts use 10 g (0.353 oz). Smaller driveshafts use 5 g (0.176 oz). 9. Remove the test weight, then install the recommended weight at the position directed by the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix). Using a metal band and epoxy, secure the test weight to the driveshaft, as shown in the figure below. 1. Test weight. 2. Measure in this direction. 3. Driveshaft diameter. 4. Directional rotation. 5. Balance weight relative to test weight centerline. - The results are displayed with respect to the location to where the test weight was placed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 3574 All vehicles 10. Using the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run a third test to verify the repair. Driveshaft Balancing - Hose Clamp Method 1. Install 1 or 2 hose clamps on the driveshaft, near the rear. Position of the hose clamp head(s) can be determined through trial and error. 2. Mark the rear of the driveshaft into 4 approximately equal sectors and number the marks 1 through 4. Install a hose clamp on the driveshaft with its head at position No. 1, as shown in the figure below. Check for vibration at road speed. Recheck with the clamp at each of the other positions to find the position that shows minimum vibration. If 2 adjacent positions show equal improvement, position the clamp head between them. 3. If the vibration persists, add a second clamp at the same position and recheck for vibration. 4. If no improvement is noted, rotate the clamps in opposite directions, equal distances from the best position determined in Step 2. Separate the clamp heads about 13 mm (1/2 in) and recheck for vibration at the road speed. 5. Repeat the process with increasing separation until the best combination is found or the vibration is reduced to an acceptable level. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 3575 Drive/Propeller Shaft: Removal and Replacement Driveshaft Driveshaft Removal and Installation NOTE: The Escape Hybrid driveshaft is longer than the driveshaft in the Escape/Mariner and is not interchangeable. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the ground strap bolt. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTICE: Do not reuse the constant velocity (CV) joint bolts and washers. Install new bolts and washers or damage to the vehicle may occur. Remove and discard the 6 front driveshaft-to-transfer case bolts and washers. - To install, tighten to 40 Nm (30 lb-ft). 4. Index-mark the front driveshaft to the center bearing. 5. NOTICE: Do not reuse the bolts and cap straps for the center U-joint. Install new bolts and cap straps or damage to the vehicle may Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 3576 occur. NOTE: There is a difference in the length of the head of the replacement cap strap bolts from the production bolts. The longer head pinion bolts can be used in either location. Remove and discard the 4 U-joint cap strap bolts and 2 cap straps and remove the front driveshaft. - To install, tighten to 23 Nm (17 lb-ft). 6. Index-mark the pinion and yoke to the driveshaft. 7. NOTE: Do not reuse the bolts for the rear U-joint flange. Install new bolts. Remove and discard the 4 rear driveshaft-to-pinion flange bolts. - To install, tighten to 70 Nm (52 lb-ft). 8. With the help of an assistant, remove the center bearing support nuts and the driveshaft. - To install, tighten to 55 Nm (41 lb-ft). 9. NOTE: If a driveshaft is installed and driveshaft vibration is encountered after installation, index the driveshaft. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 center and rear joints consist of: - 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. - staked in place U-joints are not serviced individually. If worn or damaged, install a new driveshaft assembly. - snap ring type U-joints can be replaced if worn or damaged. The U-joints allow the speeding up and slowing down of the driveshaft as the angularity of the driveshaft changes. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 3580 Universal Joint: Service and Repair Driveshaft Universal Joint - Snap Ring Type Disassembly 1. Remove the driveshaft. For additional information, refer to Driveshaft See: Drive/Propeller Shaft/Service and Repair/Removal and Replacement. 2. NOTICE: Do not, under any circumstance, clamp the driveshaft assembly in the jaws of a vise or similar holding fixture. Denting or localized fracturing may result, causing driveshaft failure during vehicle operation. Place the driveshaft on a suitable workbench. Do not damage the tube. 3. NOTE: If the components are not marked and therefore installed incorrectly, driveshaft imbalance can occur. Index-mark the driveshaft components. 4. Remove and discard all 4 of the snap rings. 5. Place the C-Frame and Screw Installer/Remover in a vise. 6. NOTE: If necessary, use a pair of pliers to remove a bearing cup that fails to press out all the way. Remove the bearing cups and the driveshaft slip yoke. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 3581 1. Position the driveshaft slip yoke in the C-Frame and Screw Installer/Remover. 2. Press out a bearing cup. 3. Rotate the driveshaft slip yoke 180 degrees. 4. Press on the U-joint spider to remove the remaining bearing cup. 5. Remove the driveshaft slip yoke. 7. Repeat steps to remove the remaining bearing cups and the U-joint spider from the driveshaft yoke. 8. NOTE: Inspect the bearing cup bores and retaining ring grooves. Remove any rust or other surface irregularities. Inspect the bearing cup bores of the driveshaft slip yoke and driveshaft yoke. Make sure that the bearing cup bores are clean and smooth. Assembly 1. NOTE: Install the U-Joint Kits as complete assemblies only. Do not mix components from other U-Joint Kits. NOTE: Lubricate the driveshaft slip yoke and driveshaft yoke bearing cup bores with grease before installing the bearing cups. Install a new U-joint spider and bearing cup. 1. Start a new bearing cup in the driveshaft yoke. - Check the needle bearings for correct positioning. 2. Position the new U-joint spider in the driveshaft yoke. 3. Using the C-Frame and Screw Installer/Remover, press the bearing cup to just below the snap ring groove. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 3582 2. NOTICE: Never mix yellow and black snap rings on opposing sides or damage to the component can occur. Remove the shaft from the C-Frame and Screw Installer/Remover and install a new yellow snap ring. 3. Repeat steps to install the new bearing cup and snap ring on the opposite side of the driveshaft yoke. - If the yellow snap ring will not seat in the snap ring groove, install the black snap rings. 4. Install the driveshaft slip yoke and new bearing cup. 1. Align the index marks made during disassembly and install the driveshaft slip yoke on the U-joint spider. 2. Start a new bearing cup in the driveshaft slip yoke. - Check the needle bearings for correct positioning. 3. Position the assembly in the C-Frame and Screw Installer/Remover. 4. Press the bearing cup to just below the snap ring groove. 5. Remove the driveshaft from the C-Frame and Screw Installer/Remover and install a new yellow snap ring. 6. NOTICE: Never mix yellow and black snap rings on opposing sides or damage to the component can occur. Repeat steps to install the new bearing cup and snap ring on the opposite side of the driveshaft slip yoke. - If the yellow snap ring will not seat in the snap ring groove, install the black snap rings. 7. NOTICE: Do not strike the bearings or damage to the component can occur. A sharp rap on the driveshaft yoke with a brass or plastic hammer will seat the bearing cups. 8. Rotate the driveshaft yoke to make sure the U-joints are free to rotate easily, without binding, before installing the driveshaft. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 3583 9. Install the driveshaft. For additional information, refer to Driveshaft See: Drive/Propeller Shaft/Service and Repair/Removal and Replacement. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Install the flywheel and the bolts. Tighten the bolts in the sequence shown in the following 3 stages: Stage 1: Tighten to............................................................................................................................... ..........................................................50 Nm (37 lb-ft). Stage 2: Tighten to.......................................... ...............................................................................................................................................80 Nm (59 lb-ft). Stage 3: Tighten to................................................................................................................ .......................................................................112 Nm (83 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 3587 Flywheel: Diagrams Lower End Components - Exploded View Crankshaft Pulley and Crankshaft Front Oil Seal Flywheel and Crankshaft Rear Oil Seal Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 3588 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Testing and Inspection > Flywheel Runout Check Flywheel: Testing and Inspection Flywheel Runout Check Flywheel Runout Check NOTICE: Do not clean the dual mass flywheel with any kind of fluid. Use a dry cloth only or damage to the dual mass flywheel may occur. NOTICE: Do not clean the gap between the primary and secondary mass. Only clean the bolt connection surface and the clutch surface or damage to the flywheel may occur. 1. Check the transaxle fluid level and fill to the correct level as necessary. 2. With the engine operating at idle and the transaxle in NEUTRAL, listen and check for unacceptable noise. Determine if any unacceptable noise is reduced when the clutch pedal is depressed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Testing and Inspection > Flywheel Runout Check > Page 3591 Flywheel: Testing and Inspection Flywheel Inspection Flywheel Inspection NOTICE: Do not clean the dual mass flywheel with any kind of fluid, use a dry cloth only or damage to the dual mass flywheel may occur. NOTICE: Do not clean the gap between the primary and secondary mass. Only clean the bolt connection surface and the clutch surface or damage to the flywheel may occur. 1. Check the transaxle fluid level and fill to the correct level as necessary. 2. With the engine operating at idle and the transaxle in NEUTRAL, listen and check for unacceptable noise. Determine if any unacceptable noise is reduced when the clutch pedal is depressed. 3. If unacceptable noise is identified, remove the transaxle. 4. Inspect the clutch slave cylinder for leaks. If a leak is identified, install a new clutch slave cylinder. 5. Inspect the sliding surfaces of the clutch release hub and bearing. Any scoring or burr should be removed with a fine grade of emery paper. 6. Inspect the transaxle input shaft for spline wear, scoring or burrs. Any scoring or burr should be removed with a fine grade of emery paper. If spline wear is identified, install a new transaxle. 7. NOTE: The clutch disc should be discarded due to possible hub spline wear or friction material wear. Remove the clutch disc and pressure plate. - Discard the clutch disc. 8. Inspect the clutch pressure plate and diaphragm spring segments and discard as necessary. - Inspect the clutch pressure plate for scoring, cracks or discoloration. Any minor scoring or discoloration should be removed with a fine grade of emery cloth. - Inspect the clutch diaphragm spring segments for damage, uneven height, scoring, cracks or discoloration. Any minor scoring or discoloration should be removed with a fine grade of emery cloth. 9. NOTE: The flywheel cannot be machined. With the dual mass flywheel installed on the engine, inspect the dual mass flywheel surface for scoring, cracks, discoloration or damage. If any of these conditions exist, install a new flywheel. 10. Using a suitable long screwdriver or bar, firmly rotate the secondary mass clockwise and counterclockwise until the dual mass flywheel friction control plate is centered between the secondary mass notches. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Testing and Inspection > Flywheel Runout Check > Page 3592 11. Inspect the dual mass flywheel friction control plate for damage or melting and install a new dual mass flywheel if necessary. 12. NOTE: The dual mass flywheel rotational freeplay inspection cannot be carried out if the friction control plate is off center or damaged. With the dual mass flywheel installed on the engine, inspect the dual mass flywheel rotational freeplay using the following Steps 13 through 17. 13. Check that the dual mass flywheel friction control plate is centered between the secondary mass notches. 14. Place a reference mark on the secondary mass of the dual mass flywheel. 15. Using light hand pressure, rotate the secondary mass clockwise to the end of the freeplay. Place a reference mark on the primary mass of the dual mass flywheel, in line with the reference mark on the secondary mass. 16. Using light hand pressure, rotate the secondary mass counterclockwise to the end of the freeplay. Place a second reference mark on the primary mass of the dual mass flywheel, in line with the reference mark on the secondary mass. 17. Measure the rotational freeplay XX between the 2 reference marks on the primary mass of the dual mass flywheel. If the rotational freeplay exceeds 19 mm (0.750 in), install a new dual mass flywheel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Testing and Inspection > Flywheel Runout Check > Page 3593 18. With the dual mass flywheel installed on the engine, inspect the dual mass flywheel internal spring operation using the following Steps 19 through 21. 19. Install the Flywheel Holding Tool. 20. Using a suitable long screwdriver or bar, firmly rotate the secondary mass clockwise. The secondary mass should begin to engage the internal spring past the freeplay movement of 19 mm (0.750 in) maximum. The secondary mass should continue to rotate and engage the internal spring with increasing spring pressure. If the secondary mass does not rotate, install a new dual mass flywheel. 21. Using a suitable long screwdriver or bar, firmly rotate the secondary mass counterclockwise. The secondary mass should begin to engage the internal spring past the freeplay movement of 19 mm (0.750 in) maximum. The secondary mass should continue to rotate and engage the internal spring with increasing spring pressure. If the secondary mass does not rotate, install a new dual mass flywheel. 22. Inspect the dual mass flywheel when removed from the engine and placed on a bench, using the following Steps 23 and 24. 23. NOTE: Blocks must be placed under the dual mass flywheel to make sure it is level and stable. Remove the dual mass flywheel and place it on a firm and level surface. - Discard the dual mass flywheel retaining bolts and remove the Flywheel Holding Tool. 24. NOTE: Axial movement of the secondary mass flywheel is normal and the dual mass flywheel should not be discarded based on this movement. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Testing and Inspection > Flywheel Runout Check > Page 3594 Using the Dial Indicator Gauge with Holding Fixture, inspect the dual mass flywheel hub bush for wear and install new as necessary. - Place a dial indicator gauge at a point on the outer upper surface of the secondary mass. - Using light hand pressure, press downward at the opposite point on the outer upper surface of the secondary mass and note the deflection on the dial indicator gauge. - Repeat this measurement at 120 degree intervals around the dual mass flywheel and note any deflection. If the deflection exceeds 1.5 mm (0.060 in) at any point, install a new dual mass flywheel. 25. Inspect the rear face of the engine block. 1. Make sure that the 2 engine dowel pins are correctly installed and are not damaged, install new dowel pins as necessary. 2. Inspect the upper and lower engine block rear face plates for damage or warping and install new plates as necessary. 3. Inspect the crankshaft flange for residual thread locking compound or rust, and clean as necessary. 26. Inspect the transaxle mounting face. - Make sure that the 2 dowel pin holes are not elongated or damaged. 27. Inspect the dual mass flywheel crankshaft mounting flange for residual thread locking compound or rust and clean as necessary. 28. NOTE: Install new dual mass flywheel retaining bolts. Loosely install the dual mass flywheel. 29. Install the Flywheel Holding Tool. 30. Tighten the dual mass flywheel retaining bolts in the sequence shown to 112 Nm (83 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Testing and Inspection > Flywheel Runout Check > Page 3595 31. NOTE: A new clutch disc should be installed due to possible hub spline wear or friction material wear. Install the clutch disc and pressure plate. 32. Install the transaxle. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Testing and Inspection > Page 3596 Flywheel: Service and Repair Flywheel Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the engine. For additional information, refer to Engine See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine - Removal. 3. Remove the 6 bolts and the flywheel. Installation 1. NOTE: Special bolts are used for installation. Do not use standard bolts. Install the flywheel and tighten the bolts in the sequence shown in the following 3 stages: - Stage 1: Tighten to 50 Nm (37 lb-ft). - Stage 2: Tighten to 80 Nm (59 lb-ft). - Stage 3: Tighten to 112 Nm (83 lb-ft). 2. Install the engine. For additional information, refer to Engine See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine - Removal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3604 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3605 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3606 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3607 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3608 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3609 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3610 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3611 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3612 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3613 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3614 Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3615 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3616 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3617 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3618 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3619 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3620 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3621 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3622 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3623 Control Module: Connector Views Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3624 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3625 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3626 Control Module: Electrical Diagrams Transaxle Control Module (TCM) 29-1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3627 29-2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Page 3628 Control Module: Testing and Inspection Transaxle Control Module (TCM) Reprogramming WARNING: THIS VEHICLE IS EQUIPPED WITH HIGH VOLTAGE CABLES, COMPONENTS, AND WIRING. THE HIGH VOLTAGE WARNING LABELS CONTAINING THE HIGH VOLTAGE SYMBOL ARE LOCATED ON EACH HIGH VOLTAGE COMPONENT. HIGH VOLTAGE CABLES AND WIRING ARE ORANGE IN COLOR. CERTIFIED RUBBER INSULATING GLOVES AND A FACE SHIELD MUST BE WORN WHEN WORKING WITH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING. THE IGNITION KEY MUST BE CYCLED TO THE OFF POSITION FOR A MINIMUM OF 5 MINUTES, AND THE HIGH VOLTAGE TRACTION BATTERY SERVICE DISCONNECT PLUG PLACED IN THE SERVICING/SHIPPING POSITION BEFORE DISCONNECTING THE HIGH VOLTAGE CABLES. DO NOT DISCONNECT, DISABLE, OR TOUCH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING DURING THE MODULE REPROGRAMMING PROCEDURE BECAUSE HIGH VOLTAGE IS PRESENT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH. Description Note: After the TCM is successfully reprogrammed clear the continuous diagnostic trouble codes (DTCs) in the powertrain control module (PCM) and the TCM that may have been stored during reprogramming. Changes made to the strategy or calibration may require TCM reprogramming. Refer to the Module Programming instructions on the scan tool. Making Changes To The TCM Calibration If the TCM does not complete the reflash after two consecutive attempts, follow the instructions listed below: 1. If the TCM reprogramming aborts during the procedure: - Reprogram the TCM again. - After the TCM reprogramming is successfully completed, clear the continuous DTCs in the PCM and the TCM. 2. If the TCM reprogramming aborts immediately after the start: - Turn the key OFF. - Disconnect the PCM body/cowl connector, and leave it disconnected. - Turn the key ON. - Start the TCM reprogramming. - After the TCM reprogramming is successfully completed, turn the key OFF and connect the PCM body/cowl connector. - Clear any PCM and TCM DTCs that may have been stored during reprogramming. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3633 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3634 Control Module: Service and Repair 4X4 Control Module Removal and Installation 1. Remove the floor console. 2. Disconnect the electrical connector. 3. Lift upward on the module to release the fasteners from the shifter base. Remove the 4X4 control module. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Mode Switch, CVT > Component Information > Diagrams Transmission Mode Switch: Diagrams Electrical Connectors C2096 (Vehicle Harness Side) C2096 (Component Side) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations Transmission Position Switch/Sensor: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 3643 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 3644 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 3645 Transmission Position Switch/Sensor: Description and Operation Transmission Range (TR) Sensor Overview The TR sensor communicates the gear selector position the driver selects to the PCM. The PCM determines a gear mode based on the TR input and the vehicle speed signal. The PCM then broadcasts a gear mode message over the communication link. The TCM uses the gear mode message to engage the transaxle in the gear the driver selected. The other control modules use the gear mode message to control the rear lamps or a brake shift interlock solenoid. The TR sensor is mounted at the base of the gear selector assembly and the sensor shaft is moved by the selector. Transmission Range (TR) Sensor TR Sensor and PCM Interface The TR sensor is a linear potentiometer device that provides the PCM with a percentage of input voltage proportional to the rotational angle of the sensor shaft. The TR sensor consists of: - two independent (TR-A1 and TR-A2) signals - two 5 volt reference (TR-VREF1 and TR-VREF2) lines - two signal return (TR-RTN1 and TR-RTN2) lines The TR-A1 signal has a negative voltage slope, meaning the voltage decreases when the sensor angle increases. The typical TR voltage ranges from approximately 4.3 volts in the PARK position to approximately 0.6 volt in the LOW gear position. The TR-A2 signal has a positive voltage slope. Voltages increase as the sensor angle increases. The typical voltage for the TR-A2 is about 1 volt in the PARK position to about 4.4 volts in the LOW gear position. The TR-VREF circuits are bussed together internal to the TR sensor, and both TR-RTN circuits are bussed together in the TR sensor. One of the TR-VREF and one of the TR-RTN circuits are dedicated signals from the PCM. This design of redundant signals protects against an open circuit condition. Voltage Versus Angle and Gear Selected Chart If the PCM detects a concern in one of TR signal inputs, it uses the other TR signal to determine what gear the driver selects. If the PCM detects one or more TR signals that are invalid, the PCM: - allows the vehicle to travel in DRIVE position or LOW gear position if the vehicle was driving forward at a significant speed when the concern was detected. - allows the vehicle to travel in REVERSE gear if the vehicle was driving backwards at a significant speed when the concern was detected. - broadcasts gear mode - NEUTRAL over the communication link when vehicle speed decreases to 8 km/h (5 mph). - sets the DTC and illuminates the indicator. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 3651 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-16 > Jun > 09 > 4X4 System - PTU Whining Noise At 60-70 MPH Case: Customer Interest 4X4 System - PTU Whining Noise At 60-70 MPH TSB 09-12-16 06/29/09 4WD, AUTOMATIC TRANSMISSION - WHINE NOISE 60-70 MPH (96-112 KM/H) FORD: 2009 Escape MERCURY: 2009 Mariner ISSUE Some 2009 Escape and Mariner vehicles equipped with automatic transmission and four wheel drive (4WD) system may exhibit a whine noise from the power transfer unit (PTU) at highway speeds 60-70 MPH (96-112 Km/h). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Add a mass damper to the lower, rear, transaxle support insulator. Refer to Workshop Manual (WSM), Section 307-01A: Automatic Transaxle/Transmission. 1. Remove the lower, rear, transaxle support insulator through-bolt. (Figure 1) 2. Add the mass damper to the lower, rear, transaxle support insulator. (Figure 2) 3. Install the through bolt and tighten to 85 +/- 13 lb-ft (115 +/- 17 N.m). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-16 > Jun > 09 > 4X4 System - PTU Whining Noise At 60-70 MPH > Page 3660 Parts Block 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 091216A 2009 Escape, Mariner 0.2 Hr. 4WD 2.5L Engine: Install Mass Damper Following Service Procedure (Do Not Use With 6038A) 091216A 2009 Escape, Mariner 0.3 Hr. 4WD 3.0L Engine: Install Mass Damper Following Service Procedure (Do Not Use With 6038A) DEALER CODING CONDITION BASIC PART NO. CODE 6068 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-4-4 > Mar > 09 > Drivetrain - Fluid leak From PTU Vent Case: Customer Interest Drivetrain - Fluid leak From PTU Vent TSB 09-4-4 03/09/09 PTU VENT BOLT LEAK - MISDIAGNOSED AS PTU SHAFT SEAL LEAK FORD: 2005-2009 Escape Hybrid, Escape MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2005-2009 Escape, Mariner, Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit a leak from the power transfer unit (PTU) vent tube bolt. This may be misdiagnosed as a PTU link shaft seal leak. Please verify leak origin and tighten PTU vent tube bolt, before replacing parts. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the PTU fill plug and check fluid level per Workshop Manual (WSM), Section 308-07B. NOTE THE FLUID LEVEL MUST BE EVEN WITH THE BOTTOM OF THE FILLER HOLE WITH THE VEHICLE ON FLAT, LEVEL GROUND. 2. Inspect PTU vent tube bolt for leak. (Figure 1) a. If PTU vent tube bolt leaking - clean bolt contact sur[aces and torque bolt to 120 +/- 19 lb-in (13.5 +/- 2.1 N.m). b. If PTU vent tube bolt not leaking - continue with normal WSM, Section 308-07B diagnosis. NOTE THIS BOLT DOES NOT REQUIRE A WASHER FOR THIS APPLICATION. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-4-4 > Mar > 09 > Drivetrain - Fluid leak From PTU Vent > Page 3665 OPERATION DESCRIPTION TIME 090404A 2005-2009 Escape, 0.5 Hr. Mariner, Escape Hybrid, 2006-2009 Mariner Hybrid: Clean Bolt Contact Surfaces, Includes Time To Check And Adjust PTU Fluid Level DEALER CODING CONDITION BASIC PART NO. CODE 7034 24 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-16 > Jun > 09 > 4X4 System - PTU Whining Noise At 60-70 MPH Case: All Technical Service Bulletins 4X4 System - PTU Whining Noise At 60-70 MPH TSB 09-12-16 06/29/09 4WD, AUTOMATIC TRANSMISSION - WHINE NOISE 60-70 MPH (96-112 KM/H) FORD: 2009 Escape MERCURY: 2009 Mariner ISSUE Some 2009 Escape and Mariner vehicles equipped with automatic transmission and four wheel drive (4WD) system may exhibit a whine noise from the power transfer unit (PTU) at highway speeds 60-70 MPH (96-112 Km/h). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Add a mass damper to the lower, rear, transaxle support insulator. Refer to Workshop Manual (WSM), Section 307-01A: Automatic Transaxle/Transmission. 1. Remove the lower, rear, transaxle support insulator through-bolt. (Figure 1) 2. Add the mass damper to the lower, rear, transaxle support insulator. (Figure 2) 3. Install the through bolt and tighten to 85 +/- 13 lb-ft (115 +/- 17 N.m). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-16 > Jun > 09 > 4X4 System - PTU Whining Noise At 60-70 MPH > Page 3671 Parts Block 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 091216A 2009 Escape, Mariner 0.2 Hr. 4WD 2.5L Engine: Install Mass Damper Following Service Procedure (Do Not Use With 6038A) 091216A 2009 Escape, Mariner 0.3 Hr. 4WD 3.0L Engine: Install Mass Damper Following Service Procedure (Do Not Use With 6038A) DEALER CODING CONDITION BASIC PART NO. CODE 6068 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-4-4 > Mar > 09 > Drivetrain - Fluid leak From PTU Vent Case: All Technical Service Bulletins Drivetrain - Fluid leak From PTU Vent TSB 09-4-4 03/09/09 PTU VENT BOLT LEAK - MISDIAGNOSED AS PTU SHAFT SEAL LEAK FORD: 2005-2009 Escape Hybrid, Escape MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2005-2009 Escape, Mariner, Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit a leak from the power transfer unit (PTU) vent tube bolt. This may be misdiagnosed as a PTU link shaft seal leak. Please verify leak origin and tighten PTU vent tube bolt, before replacing parts. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the PTU fill plug and check fluid level per Workshop Manual (WSM), Section 308-07B. NOTE THE FLUID LEVEL MUST BE EVEN WITH THE BOTTOM OF THE FILLER HOLE WITH THE VEHICLE ON FLAT, LEVEL GROUND. 2. Inspect PTU vent tube bolt for leak. (Figure 1) a. If PTU vent tube bolt leaking - clean bolt contact sur[aces and torque bolt to 120 +/- 19 lb-in (13.5 +/- 2.1 N.m). b. If PTU vent tube bolt not leaking - continue with normal WSM, Section 308-07B diagnosis. NOTE THIS BOLT DOES NOT REQUIRE A WASHER FOR THIS APPLICATION. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-4-4 > Mar > 09 > Drivetrain - Fluid leak From PTU Vent > Page 3676 OPERATION DESCRIPTION TIME 090404A 2005-2009 Escape, 0.5 Hr. Mariner, Escape Hybrid, 2006-2009 Mariner Hybrid: Clean Bolt Contact Surfaces, Includes Time To Check And Adjust PTU Fluid Level DEALER CODING CONDITION BASIC PART NO. CODE 7034 24 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3680 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3681 Control Module: Service and Repair 4X4 Control Module Removal and Installation 1. Remove the floor console. 2. Disconnect the electrical connector. 3. Lift upward on the module to release the fasteners from the shifter base. Remove the 4X4 control module. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Vibration Damper, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Vibration Damper: > 09-12-16 > Jun > 09 > 4X4 System - PTU Whining Noise At 60-70 MPH Vibration Damper: Customer Interest 4X4 System - PTU Whining Noise At 60-70 MPH TSB 09-12-16 06/29/09 4WD, AUTOMATIC TRANSMISSION - WHINE NOISE 60-70 MPH (96-112 KM/H) FORD: 2009 Escape MERCURY: 2009 Mariner ISSUE Some 2009 Escape and Mariner vehicles equipped with automatic transmission and four wheel drive (4WD) system may exhibit a whine noise from the power transfer unit (PTU) at highway speeds 60-70 MPH (96-112 Km/h). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Add a mass damper to the lower, rear, transaxle support insulator. Refer to Workshop Manual (WSM), Section 307-01A: Automatic Transaxle/Transmission. 1. Remove the lower, rear, transaxle support insulator through-bolt. (Figure 1) 2. Add the mass damper to the lower, rear, transaxle support insulator. (Figure 2) 3. Install the through bolt and tighten to 85 +/- 13 lb-ft (115 +/- 17 N.m). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Vibration Damper, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Vibration Damper: > 09-12-16 > Jun > 09 > 4X4 System - PTU Whining Noise At 60-70 MPH > Page 3691 Parts Block 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 091216A 2009 Escape, Mariner 0.2 Hr. 4WD 2.5L Engine: Install Mass Damper Following Service Procedure (Do Not Use With 6038A) 091216A 2009 Escape, Mariner 0.3 Hr. 4WD 3.0L Engine: Install Mass Damper Following Service Procedure (Do Not Use With 6038A) DEALER CODING CONDITION BASIC PART NO. CODE 6068 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Vibration Damper, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vibration Damper: > 09-12-16 > Jun > 09 > 4X4 System - PTU Whining Noise At 60-70 MPH Vibration Damper: All Technical Service Bulletins 4X4 System - PTU Whining Noise At 60-70 MPH TSB 09-12-16 06/29/09 4WD, AUTOMATIC TRANSMISSION - WHINE NOISE 60-70 MPH (96-112 KM/H) FORD: 2009 Escape MERCURY: 2009 Mariner ISSUE Some 2009 Escape and Mariner vehicles equipped with automatic transmission and four wheel drive (4WD) system may exhibit a whine noise from the power transfer unit (PTU) at highway speeds 60-70 MPH (96-112 Km/h). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Add a mass damper to the lower, rear, transaxle support insulator. Refer to Workshop Manual (WSM), Section 307-01A: Automatic Transaxle/Transmission. 1. Remove the lower, rear, transaxle support insulator through-bolt. (Figure 1) 2. Add the mass damper to the lower, rear, transaxle support insulator. (Figure 2) 3. Install the through bolt and tighten to 85 +/- 13 lb-ft (115 +/- 17 N.m). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Vibration Damper, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vibration Damper: > 09-12-16 > Jun > 09 > 4X4 System - PTU Whining Noise At 60-70 MPH > Page 3697 Parts Block 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 091216A 2009 Escape, Mariner 0.2 Hr. 4WD 2.5L Engine: Install Mass Damper Following Service Procedure (Do Not Use With 6038A) 091216A 2009 Escape, Mariner 0.3 Hr. 4WD 3.0L Engine: Install Mass Damper Following Service Procedure (Do Not Use With 6038A) DEALER CODING CONDITION BASIC PART NO. CODE 6068 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Transfer Case: > 09-4-4 > Mar > 09 > Drivetrain - Fluid leak From PTU Vent Fluid - Transfer Case: Customer Interest Drivetrain - Fluid leak From PTU Vent TSB 09-4-4 03/09/09 PTU VENT BOLT LEAK - MISDIAGNOSED AS PTU SHAFT SEAL LEAK FORD: 2005-2009 Escape Hybrid, Escape MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2005-2009 Escape, Mariner, Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit a leak from the power transfer unit (PTU) vent tube bolt. This may be misdiagnosed as a PTU link shaft seal leak. Please verify leak origin and tighten PTU vent tube bolt, before replacing parts. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the PTU fill plug and check fluid level per Workshop Manual (WSM), Section 308-07B. NOTE THE FLUID LEVEL MUST BE EVEN WITH THE BOTTOM OF THE FILLER HOLE WITH THE VEHICLE ON FLAT, LEVEL GROUND. 2. Inspect PTU vent tube bolt for leak. (Figure 1) a. If PTU vent tube bolt leaking - clean bolt contact sur[aces and torque bolt to 120 +/- 19 lb-in (13.5 +/- 2.1 N.m). b. If PTU vent tube bolt not leaking - continue with normal WSM, Section 308-07B diagnosis. NOTE THIS BOLT DOES NOT REQUIRE A WASHER FOR THIS APPLICATION. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Transfer Case: > 09-4-4 > Mar > 09 > Drivetrain - Fluid leak From PTU Vent > Page 3706 OPERATION DESCRIPTION TIME 090404A 2005-2009 Escape, 0.5 Hr. Mariner, Escape Hybrid, 2006-2009 Mariner Hybrid: Clean Bolt Contact Surfaces, Includes Time To Check And Adjust PTU Fluid Level DEALER CODING CONDITION BASIC PART NO. CODE 7034 24 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Transfer Case: > 09-4-4 > Mar > 09 > Drivetrain Fluid leak From PTU Vent Fluid - Transfer Case: All Technical Service Bulletins Drivetrain - Fluid leak From PTU Vent TSB 09-4-4 03/09/09 PTU VENT BOLT LEAK - MISDIAGNOSED AS PTU SHAFT SEAL LEAK FORD: 2005-2009 Escape Hybrid, Escape MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2005-2009 Escape, Mariner, Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit a leak from the power transfer unit (PTU) vent tube bolt. This may be misdiagnosed as a PTU link shaft seal leak. Please verify leak origin and tighten PTU vent tube bolt, before replacing parts. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the PTU fill plug and check fluid level per Workshop Manual (WSM), Section 308-07B. NOTE THE FLUID LEVEL MUST BE EVEN WITH THE BOTTOM OF THE FILLER HOLE WITH THE VEHICLE ON FLAT, LEVEL GROUND. 2. Inspect PTU vent tube bolt for leak. (Figure 1) a. If PTU vent tube bolt leaking - clean bolt contact sur[aces and torque bolt to 120 +/- 19 lb-in (13.5 +/- 2.1 N.m). b. If PTU vent tube bolt not leaking - continue with normal WSM, Section 308-07B diagnosis. NOTE THIS BOLT DOES NOT REQUIRE A WASHER FOR THIS APPLICATION. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Transfer Case: > 09-4-4 > Mar > 09 > Drivetrain Fluid leak From PTU Vent > Page 3712 OPERATION DESCRIPTION TIME 090404A 2005-2009 Escape, 0.5 Hr. Mariner, Escape Hybrid, 2006-2009 Mariner Hybrid: Clean Bolt Contact Surfaces, Includes Time To Check And Adjust PTU Fluid Level DEALER CODING CONDITION BASIC PART NO. CODE 7034 24 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Capacity Power Transfer Unit ............................................................................................................................. ............................................ 12.0 ounces (0.35 liters) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 3715 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ................................................................................................................................................ SAE 75W-140 High Performance Rear Axle Lubricant Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Yoke/Flange, Transfer Case > Component Information > Service and Repair Output Yoke/Flange: Service and Repair Output Flange Removal NOTE: This procedure applies to vehicles equipped with automatic transaxles. 1. Remove the driveshaft. 2. NOTICE: Rotational torque of the Power Transfer Unit (PTU) rear output shaft flange must be measured and recorded using a Nm (lb-in) torque wrench for correct pinion bearing preload when reassembled. Using the Drive Pinion Flange Holding Fixture to hold the flange, remove the pinion nut. 3. NOTE: Index-mark the Power Transfer Unit (PTU) rear output shaft flange relative to the pinion spline. Using a suitable tool such as Snap-on(R) CJ2001, remove the PTU rear output shaft flange. Installation 1. Install the PTU rear output shaft flange to engage the spline as previously marked. Install the PTU rear output shaft flange. 2. NOTICE: Do not overtighten the pinion nut. Refer to the rotational torque previously recorded with a Nm (in-lb) torque wrench. Overtightening the pinion nut will damage the collapsible spacer. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Yoke/Flange, Transfer Case > Component Information > Service and Repair > Page 3719 NOTICE: If the rotational torque is less than specification, tighten the drive pinion nut in small increments until it is within specification. Do not tighten the drive pinion nut more than 3 Nm (27 lb-in) or the collapsible spacer will be damaged. If the rotation torque is higher than specification, the collapsible spacer has been compressed too far and a new collapsible spacer must be installed. Using the Drive Pinion Flange Holding Fixture, install the pinion nut. 3. Install the driveshaft. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3724 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3725 Control Module: Service and Repair 4X4 Control Module Removal and Installation 1. Remove the floor console. 2. Disconnect the electrical connector. 3. Lift upward on the module to release the fasteners from the shifter base. Remove the 4X4 control module. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Removal Seals and Gaskets: Service and Repair Removal Input Shaft Seal Input Shaft Seal 1. Remove the Power Transfer Unit (PTU). For additional information, refer to Power Transfer Unit (PTU) See: Service and Repair/Removal and Replacement/Transfer Case - Power Transfer Unit (PTU) - Removal. 2. Remove the bolt and the vent tube. 3. Remove the 12 bolts and the PTU cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Removal > Page 3730 4. Remove the helical driven gear, idler gear and drive gear. 5. Using the PTU Linkshaft Seal Dust Shield Installer and Handle, remove the input shaft seal. 6. Clean the PTU sealing surface. Intermediate Shaft Seal Intermediate Shaft Seal 1. Remove the Power Transfer Unit (PTU). For additional information, refer to Power Transfer Unit (PTU) See: Service and Repair/Removal and Replacement/Transfer Case - Power Transfer Unit (PTU) - Removal. 2. Using the Halfshaft Oil Seal Remover and Slide Hammer, remove the intermediate shaft seal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Removal > Page 3731 Seals and Gaskets: Service and Repair Installation Input Shaft Seal Input Shaft Seal 1. Using the Driven Gear Oil Seal Installer, install the input shaft seal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Removal > Page 3732 2. NOTE: Make sure not to roll the inner input seal sealing lip when installing the drive gear. Install the helical gears. 1. Install the drive gear. Use a slight rotation to prevent damaging the inner input seal. 2. Install the idler gear. 3. Install the driven gear. 3. NOTE: The Power Transfer Unit (PTU) cover and case sealing surfaces must be free of oil before applying new sealant. Apply a 3 mm (0.11 in) bead of silicone sealant to the sealing surface of the PTU cover. Install the PTU cover and tighten the 12 PTU cover bolts in a star pattern. Tighten to 32 Nm (24 lb-ft). 4. Install the vent tube and the bolt. - Tighten to 14 Nm (124 lb-in). 5. Install the PTU. For additional information, refer to Power Transfer Unit (PTU) See: Service and Repair/Removal and Replacement/Transfer Case - Power Transfer Unit (PTU) - Removal. Intermediate Shaft Seal Intermediate Shaft Seal 1. Using the Handle and PTO Driven Gear Oil Seal Installer, install the intermediate shaft seal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Removal > Page 3733 2. Install the Power Transfer Unit (PTU). For additional information, refer to Power Transfer Unit (PTU) See: Service and Repair/Removal and Replacement/Transfer Case - Power Transfer Unit (PTU) - Removal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 3737 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 3744 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3752 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3753 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3754 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3755 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3756 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3757 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3758 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3759 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3760 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3761 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3762 Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3763 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3764 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3765 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3766 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3767 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3768 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3769 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3770 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3771 Control Module: Connector Views Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3772 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3773 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3774 Control Module: Electrical Diagrams Transaxle Control Module (TCM) 29-1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Diagram Information and Instructions > Page 3775 29-2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Page 3776 Control Module: Testing and Inspection Transaxle Control Module (TCM) Reprogramming WARNING: THIS VEHICLE IS EQUIPPED WITH HIGH VOLTAGE CABLES, COMPONENTS, AND WIRING. THE HIGH VOLTAGE WARNING LABELS CONTAINING THE HIGH VOLTAGE SYMBOL ARE LOCATED ON EACH HIGH VOLTAGE COMPONENT. HIGH VOLTAGE CABLES AND WIRING ARE ORANGE IN COLOR. CERTIFIED RUBBER INSULATING GLOVES AND A FACE SHIELD MUST BE WORN WHEN WORKING WITH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING. THE IGNITION KEY MUST BE CYCLED TO THE OFF POSITION FOR A MINIMUM OF 5 MINUTES, AND THE HIGH VOLTAGE TRACTION BATTERY SERVICE DISCONNECT PLUG PLACED IN THE SERVICING/SHIPPING POSITION BEFORE DISCONNECTING THE HIGH VOLTAGE CABLES. DO NOT DISCONNECT, DISABLE, OR TOUCH THE HIGH VOLTAGE CABLES, COMPONENTS, OR WIRING DURING THE MODULE REPROGRAMMING PROCEDURE BECAUSE HIGH VOLTAGE IS PRESENT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH. Description Note: After the TCM is successfully reprogrammed clear the continuous diagnostic trouble codes (DTCs) in the powertrain control module (PCM) and the TCM that may have been stored during reprogramming. Changes made to the strategy or calibration may require TCM reprogramming. Refer to the Module Programming instructions on the scan tool. Making Changes To The TCM Calibration If the TCM does not complete the reflash after two consecutive attempts, follow the instructions listed below: 1. If the TCM reprogramming aborts during the procedure: - Reprogram the TCM again. - After the TCM reprogramming is successfully completed, clear the continuous DTCs in the PCM and the TCM. 2. If the TCM reprogramming aborts immediately after the start: - Turn the key OFF. - Disconnect the PCM body/cowl connector, and leave it disconnected. - Turn the key ON. - Start the TCM reprogramming. - After the TCM reprogramming is successfully completed, turn the key OFF and connect the PCM body/cowl connector. - Clear any PCM and TCM DTCs that may have been stored during reprogramming. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3781 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3782 Control Module: Service and Repair 4X4 Control Module Removal and Installation 1. Remove the floor console. 2. Disconnect the electrical connector. 3. Lift upward on the module to release the fasteners from the shifter base. Remove the 4X4 control module. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Mode Switch, CVT > Component Information > Diagrams Transmission Mode Switch: Diagrams Electrical Connectors C2096 (Vehicle Harness Side) C2096 (Component Side) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations Transmission Position Switch/Sensor: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 3791 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 3792 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 3793 Transmission Position Switch/Sensor: Description and Operation Transmission Range (TR) Sensor Overview The TR sensor communicates the gear selector position the driver selects to the PCM. The PCM determines a gear mode based on the TR input and the vehicle speed signal. The PCM then broadcasts a gear mode message over the communication link. The TCM uses the gear mode message to engage the transaxle in the gear the driver selected. The other control modules use the gear mode message to control the rear lamps or a brake shift interlock solenoid. The TR sensor is mounted at the base of the gear selector assembly and the sensor shaft is moved by the selector. Transmission Range (TR) Sensor TR Sensor and PCM Interface The TR sensor is a linear potentiometer device that provides the PCM with a percentage of input voltage proportional to the rotational angle of the sensor shaft. The TR sensor consists of: - two independent (TR-A1 and TR-A2) signals - two 5 volt reference (TR-VREF1 and TR-VREF2) lines - two signal return (TR-RTN1 and TR-RTN2) lines The TR-A1 signal has a negative voltage slope, meaning the voltage decreases when the sensor angle increases. The typical TR voltage ranges from approximately 4.3 volts in the PARK position to approximately 0.6 volt in the LOW gear position. The TR-A2 signal has a positive voltage slope. Voltages increase as the sensor angle increases. The typical voltage for the TR-A2 is about 1 volt in the PARK position to about 4.4 volts in the LOW gear position. The TR-VREF circuits are bussed together internal to the TR sensor, and both TR-RTN circuits are bussed together in the TR sensor. One of the TR-VREF and one of the TR-RTN circuits are dedicated signals from the PCM. This design of redundant signals protects against an open circuit condition. Voltage Versus Angle and Gear Selected Chart If the PCM detects a concern in one of TR signal inputs, it uses the other TR signal to determine what gear the driver selects. If the PCM detects one or more TR signals that are invalid, the PCM: - allows the vehicle to travel in DRIVE position or LOW gear position if the vehicle was driving forward at a significant speed when the concern was detected. - allows the vehicle to travel in REVERSE gear if the vehicle was driving backwards at a significant speed when the concern was detected. - broadcasts gear mode - NEUTRAL over the communication link when vehicle speed decreases to 8 km/h (5 mph). - sets the DTC and illuminates the indicator. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Page 3802 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 3809 Electronic Brake Control Module: Diagrams Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 3810 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 3811 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module NOTE: Non-hybrid vehicles shown, hybrid vehicles similar. Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: Do not swap ABS modules between vehicles, the ABS module and the Hydraulic Control Unit (HCU) are calibrated as an assembly. All vehicles 1. Remove the HCU. For additional information, refer to Hydraulic Control Unit (HCU) - Hybrid See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair. Non-hybrid vehicles Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 3812 2. Remove the Hydraulic Control Unit (HCU) See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair. For additional information, refer to Hydraulic Control Unit (HCU) See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair. 3. Remove the jumper tube assembly bracket nut. - To install, tighten to 9 Nm (80 lb-in). 4. Disconnect the jumper tubes fittings from the HCU and remove the jumper tube assembly. - To install, tighten to 15 Nm (133 lb-in). All vehicles 5. Remove the 4 ABS module screws and the ABS module. - To install, tighten to 2 Nm (18 lb-in). 6. To install, reverse the removal procedure. 7. Configure the ABS module. 8. Calibrate the ABS module. - For non-hybrid vehicles, carry out the IVD Initialization sequence following the scan tool directions. - For hybrid vehicles, carry out the Multi-Calibration routine following the scan tool directions. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) - Hybrid Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Remove the Hydraulic Control Unit (HCU) heat shield. - Remove the 2 heat shield bolts. To install, tighten to 5 Nm (44 lb-in). 2. Disconnect the electrical connector by rotating the protective cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 3816 3. Disconnect the master cylinder brake tube fittings from the HCU. - To install, tighten to 23 Nm (17 lb-ft). 4. NOTE: Note the order of the brake tubes. Disconnect the brake tube-to-HCU fittings (12 mm). - To install, tighten to 15 Nm (133 lb-in). 5. Remove the 3 HCU bracket-to-frame bolts. - To install, tighten to 20 Nm (177 lb-in). 6. Disconnect the brake tube from the routing clip located at the bottom of the HCU bracket. 7. Remove the HCU assembly. 8. NOTE: Use care not to cross the tubes during installation. If the brake tubes are crossed, the ABS module will set DTCs during an ABS event. To install, reverse the removal procedure. - Bleed the brake system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 3820 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 3821 Traction Control Switch: Service and Repair Stability/Traction Control Switch Removal and Installation 1. Remove the lower Instrument Cluster (IC) center finish panel. 2. Depress the 2 tabs and remove the stability/traction control switch assembly. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams > Page 3825 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Brake Booster Travel Sensor - Hybrid Removal and Installation 1. Disconnect the brake booster travel sensor electrical connector. 2. Release the brake booster travel sensor retainer ring and remove the travel sensor. 3. To install, reverse the removal procedure. 4. Following the scan tool instructions, carry out the multi-calibration routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel Wheel Speed Sensor: Customer Interest ABS/TCS - Clicking Noise From Left Front Wheel TSB 09-5-5 03/23/09 LEFT FRONT ABS SENSOR CONTACTING TONE RING - VEHICLES BUILT 10/21/2008-10/31/2008 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built from 10/21/2008 to 10/31/2008 may exhibit a clicking or rubbing noise from the left front wheel speed sensor and/or exhibit ABS warning light activation. The left front wheel knuckle may have been machined incorrectly allowing the wheel speed sensor to contact the tone ring. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Measure the air gap between the left front wheel speed sensor and tone ring with a feeler gage. 2. If 0.02" (0.50 mm) or more - this procedure does not apply. Continue with normal diagnostics. 3. If less than 0.02" (0.5 mm) or evidence of contact - replace the left front wheel knuckle per Workshop Manual (WSM), Section 204-01 and the left front Wheel Speed Sensor per WSM, Section 206-09. Parts Block 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 090505A 2009 Escape Hybrid, 1.3 Hrs. Mariner Hybrid: Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Be Claimed With Operations B And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505A 2009 Escape, Mariner: 1.2 Hrs. Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel > Page 3834 Be Claimed With Operations B And/Or C (Do Not Use With 2001 B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505B 2009 Escape, Mariner, 0.6 Hr. Escape Hybrid, Mariner Hybrid: Check Caster, Camber And Toe In Can Be Claimed With Operation A And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505C 2009 Escape, Mariner, 0.2 Hr. Escape Hybrid, Mariner Hybrid: Correct Toe-In Can Be Claimed With Operation A And B (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 3K186 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel Wheel Speed Sensor: All Technical Service Bulletins ABS/TCS - Clicking Noise From Left Front Wheel TSB 09-5-5 03/23/09 LEFT FRONT ABS SENSOR CONTACTING TONE RING - VEHICLES BUILT 10/21/2008-10/31/2008 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built from 10/21/2008 to 10/31/2008 may exhibit a clicking or rubbing noise from the left front wheel speed sensor and/or exhibit ABS warning light activation. The left front wheel knuckle may have been machined incorrectly allowing the wheel speed sensor to contact the tone ring. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Measure the air gap between the left front wheel speed sensor and tone ring with a feeler gage. 2. If 0.02" (0.50 mm) or more - this procedure does not apply. Continue with normal diagnostics. 3. If less than 0.02" (0.5 mm) or evidence of contact - replace the left front wheel knuckle per Workshop Manual (WSM), Section 204-01 and the left front Wheel Speed Sensor per WSM, Section 206-09. Parts Block 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 090505A 2009 Escape Hybrid, 1.3 Hrs. Mariner Hybrid: Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Be Claimed With Operations B And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505A 2009 Escape, Mariner: 1.2 Hrs. Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel > Page 3840 Be Claimed With Operations B And/Or C (Do Not Use With 2001 B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505B 2009 Escape, Mariner, 0.6 Hr. Escape Hybrid, Mariner Hybrid: Check Caster, Camber And Toe In Can Be Claimed With Operation A And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505C 2009 Escape, Mariner, 0.2 Hr. Escape Hybrid, Mariner Hybrid: Correct Toe-In Can Be Claimed With Operation A And B (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 3K186 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 3843 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 3844 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 3845 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 3848 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 3849 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 3850 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front Wheel Speed Sensor - Front Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector is located in the engine compartment. Disconnect the electrical connector. 3. NOTICE: Care must be taken during the removal of the grommet to prevent damage. If the grommet is damaged, a new sensor may need to be installed, even though the sensor is functional in all other aspects. Remove the grommet from the body. - When removing the body grommet, rotate the grommet into a position which allows the use of a small screwdriver to release the tabs on the underside of the body grommet. These 2 tabs are located at right angles to the sensor wire. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 3853 4. Remove the front wheel speed sensor harness from the retainer. 5. Remove the front wheel speed sensor harness-to-body bolt. - To install, tighten to 9 Nm (80 lb-in). 6. Remove the front wheel speed sensor harness-to-strut bracket bolt. - To install, tighten to 15 Nm (133 lb-in). 7. Remove the front wheel speed sensor bolt from the wheel knuckle. - To install, tighten to 9 Nm (80 lb-in). 8. NOTE: Clean off any foreign material that may have collected around the sensor before removal. Remove the front wheel speed sensor. 9. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 3854 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTICE: Care must be taken during the removal of the grommet to prevent damage. If the grommet is damaged, a new sensor may need to be installed, even though the sensor is functional in all other aspects. Remove the grommet from the body. - When removing the body grommet, rotate the grommet into a position which allows the use of a small screwdriver to release the tabs on the underside of the grommet. These 2 tabs are located at right angles to the sensor wire. 3. Disconnect the rear wheel speed sensor electrical connector. 4. Remove the rear wheel speed sensor harness from the harness retainer. 5. Remove the 3 rear wheel speed sensor harness bolts. - To install, tighten to 9 Nm (80 lb-in). 6. NOTE: Clean off any debris that may have collected around the sensor before removal. Remove the rear wheel speed sensor bolt from the wheel knuckle. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 3855 - To install, tighten to 9 Nm (80 lb-in). 7. Remove the rear wheel speed sensor. 8. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 3856 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring - Front Wheel Speed Sensor Ring - Front Removal 1. Remove the front halfshaft. 2. Using a suitable driver, remove the ABS wheel speed sensor ring. Installation Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 3857 1. Install the new ABS wheel speed sensor ring and the tools on the halfshaft as shown in the previous illustration. 2. Install the ABS wheel speed sensor ring to the dimension as shown. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 3858 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring - Rear Wheel Speed Sensor Ring - Rear Removal and Installation Front Wheel Drive (FWD) vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the rear wheel hub nut. - To install, tighten to 290 Nm (214 lb-ft). 3. Remove the sensor ring from the wheel hub. 4. To install, reverse the removal procedure. All-Wheel Drive (AWD) vehicles 5. The rear wheel speed sensor ring is integral to the rear axle halfshaft and cannot be repaired separately. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding Brake Bleeding: Service and Repair Component Bleeding Master Cylinder Component Bleeding Master Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. Hybrid vehicles 1. Disconnect the brake tubes from the master cylinder. 2. Install short brake tubes onto the primary and secondary ports of the master cylinder with the ends submerged in the brake master cylinder reservoir. 3. Fill the brake reservoir with clean, specified brake fluid. 4. NOTE: On hybrid vehicles, the brake booster push rod has an elongated slot that attaches to the brake pedal with a clevis pin. The elongated slot allows for a small amount of pedal travel (free play) to occur without the brake pedal applying pressure on the booster push rod. When performing a bleed procedure, it is important to push the pedal through the air gap, so that the clevis pin is contacting the brake booster push rod. Except when required by the scan tool, the ignition key must remain off during the bleed procedure to allow minimal force required to push through the gap. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air bubbles. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 3863 5. Remove the short brake tubes and install the brake outlet tubes. - Tighten the master cylinder brake tube fittings to specifications. Refer to Specifications. Non-hybrid vehicles 6. Place a box-end wrench on the master cylinder bleeder screw and attach a rubber drain hose to the bleeder screw. Submerge the free end of the rubber hose into the master cylinder reservoir. 7. Fill the master cylinder reservoir with clean, specified brake fluid. 8. Have an assistant pump the brake pedal until clear fluid flows from the rubber hose, without air bubbles. 9. Tighten the bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. All vehicles 10. Bleed the brake system. For additional information, refer to Brake System Bleeding See: Brake System Bleeding. Brake Caliper Component Bleeding Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was disconnected or installed new. 1. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 3864 2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 5. Apply brakes several times to verify correct brake operation. Wheel Cylinder Component Bleeding Wheel Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: It is not necessary to do a complete brake system bleed if only the wheel cylinder was disconnected or installed new. 1. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 3865 - Refill the brake master cylinder reservoir as necessary. 4. Tighten the bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 5. Apply brakes several times to verify correct brake operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 3866 Brake Bleeding: Service and Repair Brake System Bleeding Brake System Bleeding Manual Bleeding - Non-Hybrid Vehicles Only WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: Pressure bleeding the brake system is preferred to manual bleeding. NOTE: Due to the complexity of the fluid path within the hybrid brake system, it is necessary to pressure bleed this system. 1. Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake master cylinder reservoir with clean, specified brake fluid. 2. Remove the RR bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the RR bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 3. Have an assistant pump and then hold firm pressure on the brake pedal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 3867 4. Loosen the RR bleeder screw until a stream of brake fluid comes out. While an assistant maintains pressure on the brake pedal, tighten the RR bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 5. Tighten the RR bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 6. Repeat Steps 2 through 5 for the LR bleeder screw. 7. Remove the RF bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the RF bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 8. Have an assistant pump and then hold firm pressure on the brake pedal. 9. Loosen the RF bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RF bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 10. Tighten the RF bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 11. Repeat Steps 7 through 10 for the LF bleeder screw. Pressure Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new. NOTE: Pressure bleed the brake system at 207-345 kPa (30-50 psi). NOTE: Due to the complexity of the fluid path within the hybrid brake system, it is necessary to pressure bleed this system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 3868 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with clean, specified brake fluid. 2. 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 the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Make sure the bleeder tank contains enough clean, specified brake fluid to complete the bleeding operation. Remove the RR bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the RR bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 4. Open the valve on the bleeder tank. - Apply 207-345 kPa (30-50 psi) to the brake system. 5. Loosen the RR bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RR bleeder screw to specifications. Refer to Specifications. Remove the rubber hose. 6. Continue bleeding the rest of the system, going in order from the LR bleeder screw to the RF bleeder screw, ending with the LF bleeder screw. - Tighten the brake caliper and wheel cylinder bleeder screws to specifications. Refer to Specifications. 7. Close the bleeder tank valve and release the pressure. Remove the tank hose from the adapter and remove the adapter. Fill the reservoir with clean, specified brake fluid and install the reservoir cap. 8. NOTE: On hybrid vehicles, the brake booster push rod has an elongated slot that attaches to the brake pedal with a clevis pin. The elongated slot allows for a small amount of pedal travel (free play) to occur without the brake pedal applying pressure on the booster push rod. When performing a bleed procedure, it is important to push the pedal through the air gap, so that the clevis pin is contacting the brake booster push rod. Except when required by the scan tool, the ignition key must remain off during the bleed procedure to allow minimal force required to push through the gap. With the ignition off, press the brake pedal through the gap to seat the clevis pin against the brake booster push rod and then confirm the pedal is firm. - If the brake pedal feels spongy (soft), repeat the Pressure Bleeding procedure to remove any remaining air from the system. Hydraulic Control Unit (HCU) Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 3869 plastic surface, immediately wash the surface with water. NOTE: Pressure bleeding the brake system is preferred to manual bleeding. All vehicles 1. Follow the Pressure Bleeding or Manual Bleeding procedure to bleed the system. 2. Connect the scan tool and follow the ABS Service Bleed instructions. 3. Repeat the Pressure Bleeding or Manual Bleeding procedure to bleed the system. Hybrid vehicles 4. Following the scan tool instructions, carry out the Multi-Calibration Routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation Brake Pedal Assy: Description and Operation Hydraulic Brake Actuation The hydraulic brake actuation system consists of the following components: - Brake master cylinder - Brake pedal and bracket assembly - Brake tubes and hoses The hydraulic brake system is diagonally split with the LH front and RH rear brakes on one circuit and the RH front and LH rear brakes on the other circuit. Hydraulic Brake Actuation The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder. When the brake pedal is pressed, brake fluid is pushed from the master cylinder through the double-walled steel tubes and flexible hoses to the front brake calipers and rear wheel cylinders. The brake fluid enters the brake calipers and wheel cylinders, forcing brake pads and shoes outward against the brake disc/drum friction surfaces, slowing or stopping rotation. When the brake pedal is released, brake fluid pressure is relieved, returning the front and rear brake components to the unapplied position. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Page 3873 Brake Pedal Assy: Service and Repair Brake Pedal and Bracket - Hybrid Removal and Installation 1. Remove the steering column shaft. 2. NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp switch and speed control deactivator switch. These switches must be removed with the brake pedal in the at-rest position. Switch plungers must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Page 3874 Remove the stoplamp switch. 3. NOTE: The booster push rod clevis locking pin is a one-time use only part. Any time the booster push rod clevis locking pin is removed, a new booster push rod clevis locking pin should be used. NOTE: Remove the clevis locking pin by squeezing the locking tabs and pulling outward on the opposite end. Remove and discard the booster push rod clevis locking pin. 4. Disconnect the electrical connectors and detach the harness retainers. 5. Remove the brake pedal bracket upper bolt. - To install, tighten to 23 Nm (17 lb-ft). 6. Remove the brake pedal bracket upper and lower nuts. - To install, tighten to 23 Nm (17 lb-ft). 7. Remove the 4 brake booster nuts. - To install, tighten to 23 Nm (17 lb-ft). 8. Remove the brake pedal and bracket assembly. - Position the brake booster forward to allow the brake pedal and bracket assembly to clear the brake booster studs. 9. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch or the speed control deactivator switch. These switches must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing these switches with the brake pedal in any other position will result in incorrect adjustment and may damage the switches. To install, reverse the removal procedure. 10. Carry the Multi-Calibration Routine. Follow the scan tool directions. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Testing and Inspection > Brake Calipers Brake Caliper: Testing and Inspection Brake Calipers Brake System Inspection Brake Calipers 1. Inspect the brake calipers for leaks, damage to seals, and piston corrosion or binding. - If the brake caliper is leaking or otherwise damaged, install a new brake caliper. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Testing and Inspection > Brake Calipers > Page 3880 Brake Caliper: Testing and Inspection Brake Caliper Guide Pins Brake System Inspection Brake Caliper Guide Pins 1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper wear or the guide pins are difficult to move, carry out the following steps. Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for wear, damage and corrosion. If bore is worn or damaged, replace the damaged component. - Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign material from the caliper guide pin bores. Clean any remaining foreign material from the bores with brake parts cleaner and compressed air. - Assemble the caliper guide pins using new caliper seals, boots and guide pins. Use an ample amount of the specified grease to lubricate the bores and guide pins. - Inspect the brake pads. For additional information, refer to Brake System Inspection. See: Testing and Inspection/Component Tests and General Diagnostics/Brake System Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures Brake Caliper: Procedures Component Bleeding Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was disconnected or installed new. 1. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 5. Apply brakes several times to verify correct brake operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 3883 Brake Caliper: Removal and Replacement Brake Caliper Brake Caliper Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTICE: Do not allow brake fluid to overflow from the master cylinder reservoir. Brake fluid may damage the high-voltage components. NOTE: The rear brake pads will wear at approximately twice the rate of the front brake pads. 1. Remove the wheel and tire. 2. NOTICE: If the anchor housing spring is to be removed, do not force the spring off the brake caliper or damage to the spring can occur. NOTICE: Do not use any tools to remove the spring, use hand force only. Do not use excessive force or damage to the spring can occur. NOTE: The LH side brake pad anti-rattle spring must be installed with the 2-tabbed end in the upper brake caliper cavity. For the LH brake caliper, release the lower portion of the brake pad anti-rattle spring. Apply force to the center of the spring and pull outward at the bottom of the spring to remove it from the lower brake caliper cavity. 3. Rotate the spring upward and remove it from the brake caliper. 4. NOTE: The RH side brake pad anti-rattle spring must be installed with the 2-tabbed end in the lower brake caliper cavity. For the RH brake caliper, release the upper portion of the brake pad anti-rattle spring. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 3884 - Apply force to the center of the spring and pull outward at the top of the spring to remove it from the upper brake caliper cavity. 5. Rotate the spring downward and remove it from the brake caliper. 6. NOTE: The brake caliper and brake flexible hose are removed as an assembly. Disconnect the brake tube fitting from the brake flexible hose. 7. Remove and discard the retainer clip from the brake flexible hose. 8. Remove the 2 guide pin bushing caps and the 2 brake caliper guide pin bolts, position the caliper aside. - Support the caliper using mechanic's wire. 9. Remove the 2 brake pads from the caliper. 10. Remove the brake flexible hose from the brake caliper. Installation 1. Install the brake pads onto the caliper and position the brake caliper onto the anchor plate. 2. Install the 2 brake caliper guide pin bolts and the 2 bushing caps. - Tighten the bolts to 50 Nm (37 lb-ft). 3. NOTE: If present, the 2-tabbed end of the brake pad anti-rattle spring must be installed first. Install the brake pad anti-rattle spring using the following procedure: 1. Insert the tab of the spring into the brake caliper cavity. 2. Twist the tab into the cavity (LH side in the upper brake caliper cavity, RH side in the lower brake caliper cavity). 4. Rotate the brake pad anti-rattle spring and position the upper portion onto the anchor plate. 5. Position the lower portion of the brake pad anti-rattle spring onto the anchor plate. 6. Push down and inward until the upper and lower ends of the brake pad anti-rattle spring are latched and seated in the brake caliper cavities. 7. NOTICE: The latch MUST be positioned as shown, or damage to component may occur. Verify that the brake pad anti-rattle spring is correctly latched by pulling on the spring. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 3885 8. NOTE: Make sure that the brake flexible hose is not twisted. Install the brake flexible hose to the brake caliper. - Tighten to 20 Nm (177 lb-in). 9. Position the brake flexible and install a new retainer clip. 10. Attach the brake tube fitting to the brake flexible hose. - Tighten to 18 Nm (159 lb-in). 11. Bleed the brake caliper. 12. Install the wheel and tire. Disc Brake System - Exploded View Disc Brake System - Exploded View Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 3886 1. For additional information, refer to the procedures. Brake Caliper Anchor Plate Brake Caliper Anchor Plate Removal and Installation 1. NOTE: The following steps must be followed to prevent the accumulator from charging and pressurizing the brake system. Disconnect the battery. 2. Remove the Battery Junction Box (BJB) fuses 9 (50A) and 18 (50A). 3. Remove the wheel and tire. 4. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin bolts and position the caliper aside. - Support the caliper using mechanic's wire. 5. Remove the 2 brake caliper anchor plate bolts. - To install, tighten to 175 Nm (129 lb-ft). 6. Remove the brake caliper anchor plate. 7. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Brake pad minimum thickness.............................................................................................................. ........................................................3.0 mm (0.118 in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 3890 Brake Pad: Testing and Inspection Brake System Inspection Brake Pads NOTE: It is not required to install new brake pads when the brake discs are machined. 1. Inspect and measure the thickness of the brake pad friction material. For additional information, refer to Specifications. - Minor surface cracks do not require pad replacement, however, if there are missing chunks or cracks in the lining through to the backing plate, install new brake pads. - If the thickness of the friction material is less than the specified thickness, install new brake pads. - If the friction material shows taper wear that is not within specifications, install new brake pads and verify the caliper guide pins are functioning correctly. For additional information, refer to Brake Caliper Guide Pins inspection. See: Testing and Inspection/Component Tests and General Diagnostics/Brake System Inspection/Brake Caliper Guide Pins Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Disc Brake System - Exploded View Brake Pad: Service and Repair Disc Brake System - Exploded View Disc Brake System - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Disc Brake System - Exploded View > Page 3893 Brake Pad: Service and Repair Brake Pads Brake Pads Removal WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTICE: Do not allow brake fluid to overflow from the master cylinder reservoir. Brake fluid may damage the high-voltage components. NOTE: The rear brake pads will wear at approximately twice the rate of the front brake pads. 1. If necessary, using a suitable suction device, remove the brake fluid from the master cylinder reservoir until it is half filled. 2. Remove the wheel and tire. 3. NOTICE: If the brake pad anti-rattle spring is to be removed, do not force the spring off the brake caliper or damage to the spring can occur. NOTICE: Do not use any tools to remove the spring, use hand force only. Do not use excessive force or damage to the spring can occur. NOTE: The LH side brake pad anti-rattle spring must be installed with the 2-tabbed end in the upper brake caliper cavity. For the LH brake caliper, release the lower portion of the brake pad anti-rattle spring. Apply force to the center of the spring and pull outward at the bottom of the spring to remove it from the lower brake caliper cavity. 4. Rotate the spring upward and remove it from the brake caliper. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Disc Brake System - Exploded View > Page 3894 5. NOTE: The RH side brake pad anti-rattle spring must be installed with the 2-tabbed end in the lower brake caliper cavity. For the RH brake caliper, release the upper portion of the brake pad anti-rattle spring. - Apply force to the center of the spring and pull outward at the top of the spring to remove it from the upper brake caliper cavity. 6. Rotate the spring downward and remove it from the brake caliper. 7. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 guide pin bushing caps and the 2 brake caliper guide pin bolts, position the caliper aside. - Support the caliper using mechanic's wire. 8. Remove the 2 brake pads from the caliper. 9. Inspect the brake pads for wear and contamination, install new pads as necessary. 10. NOTICE: Protect the piston and boots when pushing the caliper piston into the caliper piston bores or damage to the piston or boots may occur. If installing new brake pads, using a C-clamp and worn brake pad, compress the brake caliper piston into the brake caliper. 11. Inspect the brake disc and resurface or install new as necessary. Installation 1. Using specified brake parts cleaner, clean, dry and inspect the brake caliper anchor plate. Apply a light coat of specified lubricant to the 4 brake pad contact points on the anchor plate. 2. NOTE: Make sure that the brake flexible hose is not twisted. Install the brake pads onto the caliper and position the brake caliper onto the anchor plate. 3. Install the 2 brake caliper guide pin bolts and the 2 bushing caps. - Tighten the bolts to 50 Nm (37 lb-ft). 4. NOTE: The 2-tabbed end of the brake pad anti-rattle spring must be installed first. Install the brake pad anti-rattle spring using the following procedure: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Disc Brake System - Exploded View > Page 3895 1. Insert the tab of the spring into the brake caliper cavity. 2. Twist the tab into the cavity (LH side in the upper brake caliper cavity, RH side in the lower brake caliper cavity). 5. Rotate the brake pad anti-rattle spring and position the upper portion onto the anchor plate. 6. Position the lower portion of the brake pad anti-rattle spring onto the anchor plate. 7. Push down and inward until the upper and lower ends of the brake pad anti-rattle spring are latched and seated in the brake caliper cavities. 8. NOTICE: The latch MUST be positioned as shown or damage to component may occur. Verify that the brake pad anti-rattle spring is correctly latched by pulling on the spring. 9. Install the wheel and tire. 10. Fill the brake master cylinder reservoir with clean, specified brake fluid. - Apply brakes several times to verify correct brake operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Brake Disc minimum thickness............................................................................................................. ........................................................24 mm (0.944 in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 3899 Brake Rotor/Disc: Testing and Inspection Brake System Inspection Brake Discs NOTICE: Using an impact tool without a torque socket will lead to unevenly tightened wheel nuts. This causes brake disc on-vehicle lateral runout and brake roughness. NOTE: It is generally not required to install new brake discs to address noise issues. 1. Inspect the brake discs and measure the brake disc thickness in a minimum of 4 places around the circumference of the brake disc. Record the measurements, refer to Specifications. If the brake disc is cracked or otherwise damaged, install a new brake disc. - If any measurement is below the minimum thickness specification, install a new brake disc. - If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking that varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar to that caused by pads worn down to the backing plate, should also be machined. In order to machine, discs must be above the minimum thickness specification. For additional information, refer to Specifications and Brake Disc Machining See: Service and Repair/Procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures Brake Rotor/Disc: Procedures Brake Disc Machining NOTE: Do not use a bench lathe to machine the brake discs. Use an on-vehicle brake lathe only. Read the entire operating manual and/or view the video shipped with the lathe before installing, operating or repairing the lathe. NOTE: An on-vehicle brake lathe with an automatic runout adjustment feature is preferred. However, if the lathe is not self adjusting, the lathe oscillation must be adjusted using a dial indicator. The total indicated runout target is 0.000 mm (0.000 in). The maximum indicated runout should be no more than 0.050 mm (0.002 in). If the runout adjustment (automatic or manual) is carried out correctly prior to machining, then the final brake disc runout will be within specification, and a runout measurement is not necessary after machining. NOTE: Do not machine new brake discs. NOTE: Lateral runout and disc thickness variation measurements are not required because correct adjustment of the on-vehicle brake lathe will make sure that these dimensions are within specifications. 1. Remove the wheel and tire. 2. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose may occur. NOTE: It is not necessary to disconnect the brake tube from the brake caliper. Remove the bolts and position the brake caliper or brake caliper and anchor plate assembly aside, as required. - Support the brake caliper using mechanic's wire. 3. Install the hub adapter using: - four wheel nuts on a 4-stud wheel hub. - five wheel nuts on a 5-stud wheel hub. - six wheel nuts on a 6-stud wheel hub. - four wheel nuts on a 7- or 8-stud wheel hub. - five wheel nuts on a 10-stud wheel hub. 4. Install the cutting lathe. 5. If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. The total indicated runout target is 0.000 mm (0.000 in). The maximum indicated runout should be no more than 0.050 mm (0.002 in). 6. Center the cutting head, adjust the cutting bits and install the chip deflector/silencer. 7. NOTE: The depth of the cut should be between 0.10 and 0.40 mm (0.004 and 0.015 in). Lighter cuts will cause the bit to heat up and wear faster. Heavier cuts will cause poor brake disc surface finish. Machine the brake disc. 8. Remove the lathe and the silencer. 9. Remove the wheel nuts and hub adapter. 10. Remove the metal shavings. 11. NOTE: It is not required to install new brake pads if friction material is within specifications. For additional information, refer to Specifications. Position the brake caliper or brake caliper and anchor plate assembly. - Install the bolts. - For fastener torque specifications, refer to Disc Brake System. See: Specifications 12. Install the wheel and tire. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 3902 Brake Rotor/Disc: Removal and Replacement Disc Brake System - Exploded View Disc Brake System - Exploded View 1. For additional information, refer to the procedures. Brake Disc Brake Disc Removal and Installation 1. Remove the brake caliper anchor plate. For additional information, refer to Brake Caliper Anchor Plate See: Brake Caliper/Service and Repair/Removal and Replacement/Brake Caliper Anchor Plate. 2. Remove the brake disc. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair Backing Plate: Service and Repair Brake Backing Plate Removal and Installation 1. Remove the rear wheel cylinder. For additional information, refer to Wheel Cylinder See: Wheel Cylinder/Service and Repair/Removal and Replacement. 2. Remove the brake flexible hose bracket bolt. - To install, tighten to 15 Nm (133 lb-in). 3. Compress the parking brake cable conduit locking tabs and pull the parking brake cable assembly through the backing plate. 4. Remove the rear wheel hub. 5. Remove the 4 backing plate bolts and the backing plate. - To install, tighten to 85 Nm (63 lb-ft). 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Brake drum maximum diameter........................................................................................................... ..................................................256.3 mm (10.090 in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 3910 Brake Drum: Testing and Inspection Brake System Inspection Brake Drums NOTE: It is generally not required to install new brake drums to address noise issues. 1. Inspect the brake drums and measure the brake drum diameter. Record the measurements, refer to Specifications. - If the brake drum is cracked or otherwise damaged, install a new brake drum. - If the diameter measurement is more than the maximum specification, install a new brake drum. - Heavily scored brake drums, similar to that caused by shoes worn down to the backing plate, should be machined. In order to machine, drums must be below the maximum diameter specification. - For additional information, refer to Brake Shoe / Adjustments. See: Brake Shoe/Adjustments Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 3911 Brake Drum: Service and Repair Brake Drum Removal 1. Remove the wheel and tire. 2. NOTICE: Use of a brake drum puller or a torch is not recommended. Brake drum distortion can result. NOTE: If the brake drum is seized to the wheel hub pilot diameter, tap the center of the brake drum between the wheel studs. If the brake drum binds on the brake shoes, retract the brake shoes. 1. Move the brake shoe adjuster actuator lever away from the adjuster. 2. Rotate the brake shoe adjuster screw upward to retract the brake shoes. 3. Remove the brake drum. Installation 1. Using the Brake Drum Gauge, measure the inside diameter of the brake drum. - Install a new brake drum if the inside diameter exceeds the specification stamped on the outside face of the brake drum. 2. Adjust the rear brakes. For additional information, refer to Brake Shoe Adjustment See: Brake Shoe/Adjustments. 3. Position the brake drum on the vehicle. 4. Install the wheel and tire. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Brake shoe minimum thickness............................................................................................................ ........................................................1.0 mm (0.039 in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 3915 Brake Shoe: Testing and Inspection Brake System Inspection Brake Shoes 1. Inspect and measure the thickness of the brake shoe friction material. For additional information, refer to Specifications. - Minor surface cracks do not require shoe replacement, however, if there are missing chunks or cracks in the lining through to the backing plate, install new brake shoes. - If the thickness of the friction material is less than the specified thickness, install new brake shoes. - Verify that the mounting hardware is installed correctly and operating correctly. Install new hardware as necessary. - Verify that the backing plate contact points are free of corrosion that may cause binding. Clean or install new as necessary. - Verify correct brake shoe adjustment. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 3916 Brake Shoe: Adjustments Brake Shoe Adjustment 1. Remove the brake drum. For additional information, refer to Brake Drum See: Brake Drum/Service and Repair. 2. Using the Brake Adjustment Gauge, measure the inside diameter of the brake drum. 3. Position the Brake Adjustment Gauge on the brake shoes and linings and adjust accordingly. 4. Install the brake drum. For additional information, refer to Brake Drum See: Brake Drum/Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 3917 Brake Shoe: Service and Repair Brake Shoes Removal and Installation WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and serious personal injury. 1. NOTE: If new rear brake shoes and linings are being installed, resurface the brake drums to remove glazing and to provide an equal friction surface from side-to-side. Resurfacing also corrects out-of-round and bell conditions. Remove the brake drum. For additional information, refer to Brake Drum See: Brake Drum/Service and Repair. 2. Remove the 2 brake shoe retaining springs and the 2 pins. 3. Remove the upper return spring. 4. Remove the self-adjuster and spring assembly. 5. Remove the lower return spring. 6. Remove the trailing brake shoe and parking brake actuator lever assembly. 7. Remove the leading brake shoe. - Using specified brake parts cleaner, clean and dry the brake shoe contact points on the backing plate. - Apply a thin coat of the specified silicone grease to the brake shoe contact points on the backing plate. 8. NOTE: Adjust the self-adjuster to the full retracted position to ease the installation of the brake drum. To install, reverse the removal procedure. - Adjust the rear brake shoes. For additional information, refer to Brake Shoe Adjustment See: Adjustments. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Testing and Inspection Wheel Cylinder: Testing and Inspection Brake System Inspection Wheel Cylinders 1. Inspect the wheel cylinders for leaks, damage to seals, and piston corrosion or binding. - If the wheel cylinder is leaking or otherwise damaged, install a new wheel cylinder. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures Wheel Cylinder: Procedures Wheel Cylinder Lubrication Wheel Cylinder Lubrication 1. Remove the brake drum. 2. Remove the upper and lower return springs. NOTICE: Use only specified silicone based lubricant. Use of other lubricants may cause damage to piston seals. 3. With the brake shoe return springs removed, push the leading shoe into the wheel cylinder until the shoe bottoms out. 4. Pull back the wheel cylinder dust boot (opposite depressed shoe) and apply specified lubricant around the wheel cylinder piston. - Reposition the wheel cylinder dust boot. 5. Push the trailing shoe into the wheel cylinder until the shoe bottoms out. 6. Pull back the wheel cylinder dust boot (opposite depressed shoe) and apply specified lubricant around the wheel cylinder piston. - Reposition the wheel cylinder dust boot. 7. Once both wheel cylinder pistons have been lubricated, push the pistons side-to-side at least 3 times to distribute the lubricant and verify smooth movement. 8. Install the upper and lower return springs. 9. Install the brake drum. - Adjust the rear brake shoes. Wheel Cylinder Component Bleeding Wheel Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: It is not necessary to do a complete brake system bleed if only the wheel cylinder was disconnected or installed new. 1. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 3923 free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 5. Apply brakes several times to verify correct brake operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 3924 Wheel Cylinder: Removal and Replacement Wheel Cylinder Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Remove the brake shoes. For additional information, refer to Brake Shoes See: Brake Shoe/Service and Repair. 2. Disconnect the brake tube fitting. - To install, tighten to 18 Nm (159 lb-in). 3. Remove the 2 wheel cylinder bolts and remove the wheel cylinder. - To install, tighten to 11 Nm (97 lb-in). 4. To install, reverse the removal procedure. - Bleed the wheel cylinder. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 3925 Wheel Cylinder: Overhaul Wheel Cylinder Disassembly WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 3926 has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: Removal is not necessary to disassemble, inspect, hone or overhaul the rear wheel cylinder. 1. Remove the brake drum. For additional information, refer to Brake Drum See: Brake Drum/Service and Repair. 2. Remove the upper return spring. 3. Remove the lower return spring. 4. Remove the self-adjuster and spring assembly. 5. Remove the retaining springs, the pins and the leading brake shoe. 6. Remove the trailing brake shoe and parking brake actuator lever assembly. - Clean and dry the brake backing plate. 7. Remove the bleeder screw cap. 8. Remove the bleeder screw. 9. Remove the 2 dust boots. 10. Remove the 2 pistons. 11. Remove the 2 piston seals. 12. Remove the spring. 13. Inspect the wheel cylinder bore for excessive wear, corrosion or pitting. If any of these conditions exist, a new wheel cylinder must be installed. Assembly 1. Install the spring. 2. Using clean brake fluid, lubricate and install the 2 piston seals. 3. Install the 2 pistons. 4. Install the 2 dust boots. 5. Install the bleeder screw. 6. Apply a thin coat of silicone grease to the brake shoe contact points on the backing plate. 7. Install the trailing brake shoe and parking brake actuator lever assembly. 8. Install the leading brake shoe, the pins and the retaining springs. 9. NOTE: Adjust the self-adjuster to the full retracted position to ease the installation of the brake drum. Install the self-adjuster and spring assembly. NOTICE: Use only specified silicone based lubricant. Use of other lubricants may cause damage to piston seals. 10. With the brake shoe return springs removed, push the leading shoe into the wheel cylinder until the shoe bottoms out. 11. Pull back the wheel cylinder dust boot (opposite depressed shoe) and apply the specified lubricant around the wheel cylinder piston. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 3927 - Reposition the wheel cylinder dust boot. 12. Push the trailing shoe into the wheel cylinder until the shoe bottoms out. 13. Pull back the wheel cylinder dust boot (opposite depressed shoe) and apply the specified lubricant around the wheel cylinder piston. - Reposition the wheel cylinder dust boot. 14. Once both wheel cylinder pistons have been lubricated, push the pistons side-to-side at least 3 times to distribute the lubricant and make sure of smooth movement. 15. Install the lower return spring. 16. Install the upper return spring. 17. Install the brake drum. For additional information, refer to Brake Drum See: Brake Drum/Service and Repair. - Adjust the rear brake shoes. For additional information, refer to Brake Shoe Adjustment See: Brake Shoe/Adjustments. 18. Bleed the wheel cylinder. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding Brake Bleeding: Service and Repair Component Bleeding Master Cylinder Component Bleeding Master Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. Hybrid vehicles 1. Disconnect the brake tubes from the master cylinder. 2. Install short brake tubes onto the primary and secondary ports of the master cylinder with the ends submerged in the brake master cylinder reservoir. 3. Fill the brake reservoir with clean, specified brake fluid. 4. NOTE: On hybrid vehicles, the brake booster push rod has an elongated slot that attaches to the brake pedal with a clevis pin. The elongated slot allows for a small amount of pedal travel (free play) to occur without the brake pedal applying pressure on the booster push rod. When performing a bleed procedure, it is important to push the pedal through the air gap, so that the clevis pin is contacting the brake booster push rod. Except when required by the scan tool, the ignition key must remain off during the bleed procedure to allow minimal force required to push through the gap. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air bubbles. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 3933 5. Remove the short brake tubes and install the brake outlet tubes. - Tighten the master cylinder brake tube fittings to specifications. Refer to Specifications. Non-hybrid vehicles 6. Place a box-end wrench on the master cylinder bleeder screw and attach a rubber drain hose to the bleeder screw. Submerge the free end of the rubber hose into the master cylinder reservoir. 7. Fill the master cylinder reservoir with clean, specified brake fluid. 8. Have an assistant pump the brake pedal until clear fluid flows from the rubber hose, without air bubbles. 9. Tighten the bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. All vehicles 10. Bleed the brake system. For additional information, refer to Brake System Bleeding See: Brake System Bleeding. Brake Caliper Component Bleeding Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was disconnected or installed new. 1. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 3934 2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 5. Apply brakes several times to verify correct brake operation. Wheel Cylinder Component Bleeding Wheel Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: It is not necessary to do a complete brake system bleed if only the wheel cylinder was disconnected or installed new. 1. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 3935 - Refill the brake master cylinder reservoir as necessary. 4. Tighten the bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 5. Apply brakes several times to verify correct brake operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 3936 Brake Bleeding: Service and Repair Brake System Bleeding Brake System Bleeding Manual Bleeding - Non-Hybrid Vehicles Only WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: Pressure bleeding the brake system is preferred to manual bleeding. NOTE: Due to the complexity of the fluid path within the hybrid brake system, it is necessary to pressure bleed this system. 1. Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake master cylinder reservoir with clean, specified brake fluid. 2. Remove the RR bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the RR bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 3. Have an assistant pump and then hold firm pressure on the brake pedal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 3937 4. Loosen the RR bleeder screw until a stream of brake fluid comes out. While an assistant maintains pressure on the brake pedal, tighten the RR bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 5. Tighten the RR bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 6. Repeat Steps 2 through 5 for the LR bleeder screw. 7. Remove the RF bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the RF bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 8. Have an assistant pump and then hold firm pressure on the brake pedal. 9. Loosen the RF bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RF bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 10. Tighten the RF bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 11. Repeat Steps 7 through 10 for the LF bleeder screw. Pressure Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new. NOTE: Pressure bleed the brake system at 207-345 kPa (30-50 psi). NOTE: Due to the complexity of the fluid path within the hybrid brake system, it is necessary to pressure bleed this system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 3938 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with clean, specified brake fluid. 2. 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 the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Make sure the bleeder tank contains enough clean, specified brake fluid to complete the bleeding operation. Remove the RR bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the RR bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 4. Open the valve on the bleeder tank. - Apply 207-345 kPa (30-50 psi) to the brake system. 5. Loosen the RR bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RR bleeder screw to specifications. Refer to Specifications. Remove the rubber hose. 6. Continue bleeding the rest of the system, going in order from the LR bleeder screw to the RF bleeder screw, ending with the LF bleeder screw. - Tighten the brake caliper and wheel cylinder bleeder screws to specifications. Refer to Specifications. 7. Close the bleeder tank valve and release the pressure. Remove the tank hose from the adapter and remove the adapter. Fill the reservoir with clean, specified brake fluid and install the reservoir cap. 8. NOTE: On hybrid vehicles, the brake booster push rod has an elongated slot that attaches to the brake pedal with a clevis pin. The elongated slot allows for a small amount of pedal travel (free play) to occur without the brake pedal applying pressure on the booster push rod. When performing a bleed procedure, it is important to push the pedal through the air gap, so that the clevis pin is contacting the brake booster push rod. Except when required by the scan tool, the ignition key must remain off during the bleed procedure to allow minimal force required to push through the gap. With the ignition off, press the brake pedal through the gap to seat the clevis pin against the brake booster push rod and then confirm the pedal is firm. - If the brake pedal feels spongy (soft), repeat the Pressure Bleeding procedure to remove any remaining air from the system. Hydraulic Control Unit (HCU) Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 3939 plastic surface, immediately wash the surface with water. NOTE: Pressure bleeding the brake system is preferred to manual bleeding. All vehicles 1. Follow the Pressure Bleeding or Manual Bleeding procedure to bleed the system. 2. Connect the scan tool and follow the ABS Service Bleed instructions. 3. Repeat the Pressure Bleeding or Manual Bleeding procedure to bleed the system. Hybrid vehicles 4. Following the scan tool instructions, carry out the Multi-Calibration Routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Testing and Inspection > Brake Calipers Brake Caliper: Testing and Inspection Brake Calipers Brake System Inspection Brake Calipers 1. Inspect the brake calipers for leaks, damage to seals, and piston corrosion or binding. - If the brake caliper is leaking or otherwise damaged, install a new brake caliper. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Testing and Inspection > Brake Calipers > Page 3944 Brake Caliper: Testing and Inspection Brake Caliper Guide Pins Brake System Inspection Brake Caliper Guide Pins 1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper wear or the guide pins are difficult to move, carry out the following steps. Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for wear, damage and corrosion. If bore is worn or damaged, replace the damaged component. - Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign material from the caliper guide pin bores. Clean any remaining foreign material from the bores with brake parts cleaner and compressed air. - Assemble the caliper guide pins using new caliper seals, boots and guide pins. Use an ample amount of the specified grease to lubricate the bores and guide pins. - Inspect the brake pads. For additional information, refer to Brake System Inspection. See: Testing and Inspection/Component Tests and General Diagnostics/Brake System Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures Brake Caliper: Procedures Component Bleeding Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was disconnected or installed new. 1. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 5. Apply brakes several times to verify correct brake operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 3947 Brake Caliper: Removal and Replacement Brake Caliper Brake Caliper Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTICE: Do not allow brake fluid to overflow from the master cylinder reservoir. Brake fluid may damage the high-voltage components. NOTE: The rear brake pads will wear at approximately twice the rate of the front brake pads. 1. Remove the wheel and tire. 2. NOTICE: If the anchor housing spring is to be removed, do not force the spring off the brake caliper or damage to the spring can occur. NOTICE: Do not use any tools to remove the spring, use hand force only. Do not use excessive force or damage to the spring can occur. NOTE: The LH side brake pad anti-rattle spring must be installed with the 2-tabbed end in the upper brake caliper cavity. For the LH brake caliper, release the lower portion of the brake pad anti-rattle spring. Apply force to the center of the spring and pull outward at the bottom of the spring to remove it from the lower brake caliper cavity. 3. Rotate the spring upward and remove it from the brake caliper. 4. NOTE: The RH side brake pad anti-rattle spring must be installed with the 2-tabbed end in the lower brake caliper cavity. For the RH brake caliper, release the upper portion of the brake pad anti-rattle spring. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 3948 - Apply force to the center of the spring and pull outward at the top of the spring to remove it from the upper brake caliper cavity. 5. Rotate the spring downward and remove it from the brake caliper. 6. NOTE: The brake caliper and brake flexible hose are removed as an assembly. Disconnect the brake tube fitting from the brake flexible hose. 7. Remove and discard the retainer clip from the brake flexible hose. 8. Remove the 2 guide pin bushing caps and the 2 brake caliper guide pin bolts, position the caliper aside. - Support the caliper using mechanic's wire. 9. Remove the 2 brake pads from the caliper. 10. Remove the brake flexible hose from the brake caliper. Installation 1. Install the brake pads onto the caliper and position the brake caliper onto the anchor plate. 2. Install the 2 brake caliper guide pin bolts and the 2 bushing caps. - Tighten the bolts to 50 Nm (37 lb-ft). 3. NOTE: If present, the 2-tabbed end of the brake pad anti-rattle spring must be installed first. Install the brake pad anti-rattle spring using the following procedure: 1. Insert the tab of the spring into the brake caliper cavity. 2. Twist the tab into the cavity (LH side in the upper brake caliper cavity, RH side in the lower brake caliper cavity). 4. Rotate the brake pad anti-rattle spring and position the upper portion onto the anchor plate. 5. Position the lower portion of the brake pad anti-rattle spring onto the anchor plate. 6. Push down and inward until the upper and lower ends of the brake pad anti-rattle spring are latched and seated in the brake caliper cavities. 7. NOTICE: The latch MUST be positioned as shown, or damage to component may occur. Verify that the brake pad anti-rattle spring is correctly latched by pulling on the spring. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 3949 8. NOTE: Make sure that the brake flexible hose is not twisted. Install the brake flexible hose to the brake caliper. - Tighten to 20 Nm (177 lb-in). 9. Position the brake flexible and install a new retainer clip. 10. Attach the brake tube fitting to the brake flexible hose. - Tighten to 18 Nm (159 lb-in). 11. Bleed the brake caliper. 12. Install the wheel and tire. Disc Brake System - Exploded View Disc Brake System - Exploded View Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 3950 1. For additional information, refer to the procedures. Brake Caliper Anchor Plate Brake Caliper Anchor Plate Removal and Installation 1. NOTE: The following steps must be followed to prevent the accumulator from charging and pressurizing the brake system. Disconnect the battery. 2. Remove the Battery Junction Box (BJB) fuses 9 (50A) and 18 (50A). 3. Remove the wheel and tire. 4. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin bolts and position the caliper aside. - Support the caliper using mechanic's wire. 5. Remove the 2 brake caliper anchor plate bolts. - To install, tighten to 175 Nm (129 lb-ft). 6. Remove the brake caliper anchor plate. 7. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Ford P/N .............................................................................................................................................. .................................................................... PM-1-C Ford Specification ............................................. ......................................................................................................................................... WSS-M6C62-A Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 3957 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 3961 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Testing and Inspection Brake Hose/Line: Testing and Inspection Brake System Inspection Brake Flexible Hoses and Tubes NOTICE: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which may result in brake tube failure. NOTE: Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly double flared to provide strong, leakproof connections. When bending tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube. 1. Inspect brake tubes for corrosion, cracks, leaks or any other signs of damage. - If a section of the brake tube is damaged, the entire section must be installed with a new tube of the same type, size, shape and length. - When installing the hydraulic brake tubing, hoses or connectors, tighten all connections to specifications. After installation, bleed the brake system. For additional information, refer to Brake System Bleeding See: Brake Bleeding/Service and Repair/Brake System Bleeding. 2. Inspect the brake flexible hoses for cracks, leaks and swelling during brake application or any other signs of damage. - Install a new brake flexible hose if the hose shows signs of softening, cracking or other damage. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Flexible Hose Brake Hose/Line: Service and Repair Brake Flexible Hose Brake Flexible Hose Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Disconnect the brake flexible hose fitting from the wheel cylinder. - To install, tighten to 18 Nm (159 lb-in). 2. Remove the brake flexible hose bracket bolt. - To install, tighten to 15 Nm (133 lb-in). 3. Disconnect the brake tube fitting from the brake flexible hose. - To install, tighten to 18 Nm (159 lb-in). 4. Remove the flexible hose clip and the brake hose. 5. To install, reverse the removal procedure. - Bleed the wheel cylinder. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Flexible Hose > Page 3967 Brake Hose/Line: Service and Repair Front Disc Brake Disc Brake System - Exploded View Disc Brake System - Exploded View 1. For additional information, refer to the procedures. Brake Flexible Hose Brake Flexible Hose Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Flexible Hose > Page 3968 WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Remove the wheel and tire. 2. Remove and discard the brake flexible hose retaining clip. 3. Disconnect the brake tube fitting from the brake flexible hose. - To install, tighten to 18 Nm (159 lb-in). 4. Detach the brake flexible hose from the strut bracket. 5. Disconnect the brake flexible hose from the caliper. - To install, tighten to 20 Nm (177 lb-in). 6. To install, reverse the removal procedure. - Install a new retaining clip. - Bleed the brake caliper. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) - Hybrid Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Remove the Hydraulic Control Unit (HCU) heat shield. - Remove the 2 heat shield bolts. To install, tighten to 5 Nm (44 lb-in). 2. Disconnect the electrical connector by rotating the protective cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 3972 3. Disconnect the master cylinder brake tube fittings from the HCU. - To install, tighten to 23 Nm (17 lb-ft). 4. NOTE: Note the order of the brake tubes. Disconnect the brake tube-to-HCU fittings (12 mm). - To install, tighten to 15 Nm (133 lb-in). 5. Remove the 3 HCU bracket-to-frame bolts. - To install, tighten to 20 Nm (177 lb-in). 6. Disconnect the brake tube from the routing clip located at the bottom of the HCU bracket. 7. Remove the HCU assembly. 8. NOTE: Use care not to cross the tubes during installation. If the brake tubes are crossed, the ABS module will set DTCs during an ABS event. To install, reverse the removal procedure. - Bleed the brake system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition Brake Master Cylinder: Testing and Inspection Brake Master Cylinder - Bypass Condition Component Tests Brake Master Cylinder - Bypass Condition 1. Disconnect the brake tubes from the master cylinder. 2. Plug the outlet ports of the master cylinder. 3. NOTE: Make sure the outlet port plugs do not show signs of leakage. Lightly apply the brakes and hold for 10 seconds. Release the brakes and then reapply with heavy force. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and a new brake master cylinder must be installed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 3977 Brake Master Cylinder: Testing and Inspection Brake Master Cylinder - Compensator Port Component Tests Brake Master Cylinder - Compensator Port 1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Maintenance/Service and Repair. 2. Apply and release the brakes. 3. With the brakes released, attempt to rotate each wheel and check for any brake drag. - If an excessive amount of brake drag exists at multiple wheels, continue to Step 4. - If an excessive amount of brake drag exists at only one wheel, it indicates a possible seized brake caliper, brake wheel cylinder or parking brake component. Repair or install new components as necessary. 4. Check the brake stoplamp switch and the brake pedal free play to verify that the brake pedal is not partially applied. 5. Loosen the brake master cylinder nuts and position the brake master cylinder away from the brake booster. 6. With the brakes released, attempt to rotate each wheel and check for any brake drag. - If the brake drag is no longer present, install a new brake booster. - If the brake drag is still present, install a new master cylinder. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 3978 Brake Master Cylinder: Testing and Inspection Brake System Inspection Brake Pads Brake System Inspection Brake Pads NOTE: It is not required to install new brake pads when the brake discs are machined. 1. Inspect and measure the thickness of the brake pad friction material. For additional information, refer to Specifications. - Minor surface cracks do not require pad replacement, however, if there are missing chunks or cracks in the lining through to the backing plate, install new brake pads. - If the thickness of the friction material is less than the specified thickness, install new brake pads. - If the friction material shows taper wear that is not within specifications, install new brake pads and verify the caliper guide pins are functioning correctly. For additional information, refer to Brake Caliper Guide Pins inspection. See: Testing and Inspection/Component Tests and General Diagnostics/Brake System Inspection/Brake Caliper Guide Pins Brake Shoes Brake System Inspection Brake Shoes 1. Inspect and measure the thickness of the brake shoe friction material. For additional information, refer to Specifications. - Minor surface cracks do not require shoe replacement, however, if there are missing chunks or cracks in the lining through to the backing plate, install new brake shoes. - If the thickness of the friction material is less than the specified thickness, install new brake shoes. - Verify that the mounting hardware is installed correctly and operating correctly. Install new hardware as necessary. - Verify that the backing plate contact points are free of corrosion that may cause binding. Clean or install new as necessary. - Verify correct brake shoe adjustment. Brake Discs Brake System Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 3979 Brake Discs NOTICE: Using an impact tool without a torque socket will lead to unevenly tightened wheel nuts. This causes brake disc on-vehicle lateral runout and brake roughness. NOTE: It is generally not required to install new brake discs to address noise issues. 1. Inspect the brake discs and measure the brake disc thickness in a minimum of 4 places around the circumference of the brake disc. Record the measurements, refer to Specifications. If the brake disc is cracked or otherwise damaged, install a new brake disc. - If any measurement is below the minimum thickness specification, install a new brake disc. - If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking that varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar to that caused by pads worn down to the backing plate, should also be machined. In order to machine, discs must be above the minimum thickness specification. For additional information, refer to Specifications and Brake Disc Machining See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Procedures. Brake Drums Brake System Inspection Brake Drums NOTE: It is generally not required to install new brake drums to address noise issues. 1. Inspect the brake drums and measure the brake drum diameter. Record the measurements, refer to Specifications. - If the brake drum is cracked or otherwise damaged, install a new brake drum. - If the diameter measurement is more than the maximum specification, install a new brake drum. - Heavily scored brake drums, similar to that caused by shoes worn down to the backing plate, should be machined. In order to machine, drums must be below the maximum diameter specification. - For additional information, refer to Brake Shoe / Adjustments. See: Drum Brake System/Brake Shoe/Adjustments Wheel Cylinders Brake System Inspection Wheel Cylinders Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 3980 1. Inspect the wheel cylinders for leaks, damage to seals, and piston corrosion or binding. - If the wheel cylinder is leaking or otherwise damaged, install a new wheel cylinder. Brake Calipers Brake System Inspection Brake Calipers 1. Inspect the brake calipers for leaks, damage to seals, and piston corrosion or binding. - If the brake caliper is leaking or otherwise damaged, install a new brake caliper. Brake Caliper Guide Pins Brake System Inspection Brake Caliper Guide Pins 1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper wear or the guide pins are difficult to move, carry out the following steps. Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for wear, damage and corrosion. If bore is worn or damaged, replace the damaged component. - Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign material from the caliper guide pin bores. Clean any remaining foreign material from the bores with brake parts cleaner and compressed air. - Assemble the caliper guide pins using new caliper seals, boots and guide pins. Use an ample amount of the specified grease to lubricate the bores and guide pins. - Inspect the brake pads. For additional information, refer to Brake System Inspection. See: Testing and Inspection/Component Tests and General Diagnostics/Brake System Inspection Brake Flexible Hoses and Tubes Brake System Inspection Brake Flexible Hoses and Tubes NOTICE: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which may result in brake tube failure. NOTE: Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly double flared to provide strong, Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 3981 leakproof connections. When bending tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube. 1. Inspect brake tubes for corrosion, cracks, leaks or any other signs of damage. - If a section of the brake tube is damaged, the entire section must be installed with a new tube of the same type, size, shape and length. - When installing the hydraulic brake tubing, hoses or connectors, tighten all connections to specifications. After installation, bleed the brake system. For additional information, refer to Brake System Bleeding See: Brake Bleeding/Service and Repair/Brake System Bleeding. 2. Inspect the brake flexible hoses for cracks, leaks and swelling during brake application or any other signs of damage. - Install a new brake flexible hose if the hose shows signs of softening, cracking or other damage. Brake Master Cylinder Brake System Inspection Brake Master Cylinder NOTE: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder reservoir will fall during brake application and rise during release. The net fluid level (such as after brake application and release) will remain unchanged. Fluid level will decrease with pad wear. NOTE: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This results from the normal lubricating action of the master cylinder bore and seal. 1. Inspect the brake master cylinder for fluid leaks. - Install a new master cylinder or brake fluid reservoir if signs of excessive leaking are present. - To check for correct brake master cylinder operation, refer to Component Tests See: Testing and Inspection/Component Tests and General Diagnostics. Brake Booster Brake System Inspection Brake Booster (Hybrid Vehicles) 1. Inspect the brake booster for excessive corrosion or damage. Inspect the vacuum hoses for leaks and kinks. - Install a new brake booster if signs of excessive corrosion or damage is found. - Repair or replace vacuum hoses as necessary. 2. Check all electrical connections by wiggling connectors and flexing the wire harnesses. - Repair the connector, terminals or wire harness as needed. 3. Retrieve any ABS module DTCs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures Brake Master Cylinder: Procedures Component Bleeding Master Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. Hybrid vehicles 1. Disconnect the brake tubes from the master cylinder. 2. Install short brake tubes onto the primary and secondary ports of the master cylinder with the ends submerged in the brake master cylinder reservoir. 3. Fill the brake reservoir with clean, specified brake fluid. 4. NOTE: On hybrid vehicles, the brake booster push rod has an elongated slot that attaches to the brake pedal with a clevis pin. The elongated slot allows for a small amount of pedal travel (free play) to occur without the brake pedal applying pressure on the booster push rod. When performing a bleed procedure, it is important to push the pedal through the air gap, so that the clevis pin is contacting the brake booster push rod. Except when required by the scan tool, the ignition key must remain off during the bleed procedure to allow minimal force required to push through the gap. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air bubbles. 5. Remove the short brake tubes and install the brake outlet tubes. - Tighten the master cylinder brake tube fittings to specifications. Refer to Specifications. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 3984 Non-hybrid vehicles 6. Place a box-end wrench on the master cylinder bleeder screw and attach a rubber drain hose to the bleeder screw. Submerge the free end of the rubber hose into the master cylinder reservoir. 7. Fill the master cylinder reservoir with clean, specified brake fluid. 8. Have an assistant pump the brake pedal until clear fluid flows from the rubber hose, without air bubbles. 9. Tighten the bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. All vehicles 10. Bleed the brake system. For additional information, refer to Brake System Bleeding See: Brake Bleeding/Service and Repair/Brake System Bleeding. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 3985 Brake Master Cylinder: Removal and Replacement Brake Master Cylinder Brake Master Cylinder - Hybrid Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Disconnect the brake fluid level warning switch electrical connector. 2. Using a suitable suction device, remove the brake fluid from the brake master cylinder reservoir. 3. Disconnect the 2 brake tube fittings and plug the brake tubes and the brake master cylinder ports. - To install, tighten to 23 Nm (17 lb-ft). 4. Remove and discard the 2 brake master cylinder nuts. - To install, tighten new nuts to 25 Nm (18 lb-ft). 5. Remove the brake master cylinder assembly. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 3986 6. To install, reverse the removal procedure. - Bleed the master cylinder. Brake Fluid Reservoir Brake Fluid Reservoir Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Disconnect the brake fluid level warning switch electrical connector. 2. Using a suitable suction device, remove the brake fluid from the brake master cylinder reservoir. 3. If equipped with a manual transmission, release the clamp and disconnect the clutch hose from the brake fluid reservoir. - Plug the clutch master cylinder feed hose. 4. Remove the reservoir. - Release the retaining clips on the underside of the reservoir. - Pull the reservoir upwards. 5. Remove and discard the 2 seals. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 3987 - Install new seals. Lubricate the seals with clean, specified brake fluid. - Bleed the brake system. - If equipped with a manual transmission, bleed the clutch master cylinder. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Testing and Inspection Wheel Cylinder: Testing and Inspection Brake System Inspection Wheel Cylinders 1. Inspect the wheel cylinders for leaks, damage to seals, and piston corrosion or binding. - If the wheel cylinder is leaking or otherwise damaged, install a new wheel cylinder. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures Wheel Cylinder: Procedures Wheel Cylinder Lubrication Wheel Cylinder Lubrication 1. Remove the brake drum. 2. Remove the upper and lower return springs. NOTICE: Use only specified silicone based lubricant. Use of other lubricants may cause damage to piston seals. 3. With the brake shoe return springs removed, push the leading shoe into the wheel cylinder until the shoe bottoms out. 4. Pull back the wheel cylinder dust boot (opposite depressed shoe) and apply specified lubricant around the wheel cylinder piston. - Reposition the wheel cylinder dust boot. 5. Push the trailing shoe into the wheel cylinder until the shoe bottoms out. 6. Pull back the wheel cylinder dust boot (opposite depressed shoe) and apply specified lubricant around the wheel cylinder piston. - Reposition the wheel cylinder dust boot. 7. Once both wheel cylinder pistons have been lubricated, push the pistons side-to-side at least 3 times to distribute the lubricant and verify smooth movement. 8. Install the upper and lower return springs. 9. Install the brake drum. - Adjust the rear brake shoes. Wheel Cylinder Component Bleeding Wheel Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: It is not necessary to do a complete brake system bleed if only the wheel cylinder was disconnected or installed new. 1. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 3993 free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the bleeder screw to specifications. Refer to Specifications. Remove the rubber hose and install the bleeder screw cap. 5. Apply brakes several times to verify correct brake operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 3994 Wheel Cylinder: Removal and Replacement Wheel Cylinder Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Remove the brake shoes. For additional information, refer to Brake Shoes See: Drum Brake System/Brake Shoe/Service and Repair. 2. Disconnect the brake tube fitting. - To install, tighten to 18 Nm (159 lb-in). 3. Remove the 2 wheel cylinder bolts and remove the wheel cylinder. - To install, tighten to 11 Nm (97 lb-in). 4. To install, reverse the removal procedure. - Bleed the wheel cylinder. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 3995 Wheel Cylinder: Overhaul Wheel Cylinder Disassembly WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 3996 has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: Removal is not necessary to disassemble, inspect, hone or overhaul the rear wheel cylinder. 1. Remove the brake drum. For additional information, refer to Brake Drum See: Drum Brake System/Brake Drum/Service and Repair. 2. Remove the upper return spring. 3. Remove the lower return spring. 4. Remove the self-adjuster and spring assembly. 5. Remove the retaining springs, the pins and the leading brake shoe. 6. Remove the trailing brake shoe and parking brake actuator lever assembly. - Clean and dry the brake backing plate. 7. Remove the bleeder screw cap. 8. Remove the bleeder screw. 9. Remove the 2 dust boots. 10. Remove the 2 pistons. 11. Remove the 2 piston seals. 12. Remove the spring. 13. Inspect the wheel cylinder bore for excessive wear, corrosion or pitting. If any of these conditions exist, a new wheel cylinder must be installed. Assembly 1. Install the spring. 2. Using clean brake fluid, lubricate and install the 2 piston seals. 3. Install the 2 pistons. 4. Install the 2 dust boots. 5. Install the bleeder screw. 6. Apply a thin coat of silicone grease to the brake shoe contact points on the backing plate. 7. Install the trailing brake shoe and parking brake actuator lever assembly. 8. Install the leading brake shoe, the pins and the retaining springs. 9. NOTE: Adjust the self-adjuster to the full retracted position to ease the installation of the brake drum. Install the self-adjuster and spring assembly. NOTICE: Use only specified silicone based lubricant. Use of other lubricants may cause damage to piston seals. 10. With the brake shoe return springs removed, push the leading shoe into the wheel cylinder until the shoe bottoms out. 11. Pull back the wheel cylinder dust boot (opposite depressed shoe) and apply the specified lubricant around the wheel cylinder piston. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 3997 - Reposition the wheel cylinder dust boot. 12. Push the trailing shoe into the wheel cylinder until the shoe bottoms out. 13. Pull back the wheel cylinder dust boot (opposite depressed shoe) and apply the specified lubricant around the wheel cylinder piston. - Reposition the wheel cylinder dust boot. 14. Once both wheel cylinder pistons have been lubricated, push the pistons side-to-side at least 3 times to distribute the lubricant and make sure of smooth movement. 15. Install the lower return spring. 16. Install the upper return spring. 17. Install the brake drum. For additional information, refer to Brake Drum See: Drum Brake System/Brake Drum/Service and Repair. - Adjust the rear brake shoes. For additional information, refer to Brake Shoe Adjustment See: Drum Brake System/Brake Shoe/Adjustments. 18. Bleed the wheel cylinder. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures Parking Brake Cable: Procedures Parking Brake Cable Tension Release 1. With the help of an assistant, release the parking brake cable tension by pulling down on the front cable at the cable union, until the parking brake control drum track rotates to its stop and a 4 mm (0.15 in) x 100 mm (3.93 in) retainer pin can be inserted. 2. NOTE: Before removing the brake control retaining pin, make sure all cable connections are secure and the cable tension is reloaded slowly. To reload the tension on the parking brake cable, follow the release procedure in reverse. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 4003 Parking Brake Cable: Removal and Replacement Parking Brake Cable - Rear, LH Parking Brake Cable - Rear, LH NOTE: Rear disc shown, rear drum similar. Removal and Installation 1. Release the parking brake cable tension. For additional information, refer to Parking Brake Cable Tension Release See: Procedures. 2. Remove the rear brake shoes. 3. Disconnect the parking brake cable from the cable connector and the equalizer bracket by compressing the cable conduit locking tabs. 4. Detach the cable-to-fuel tank strap pin type retainer. 5. Remove the 2 parking brake cable bracket bolts. - To install, tighten to 23 Nm (17 lb-ft). 6. Compress the rear parking brake cable conduit locking tabs and pull the cable assembly through the brake backing plate. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 4004 7. To install, reverse the removal procedure. Parking Brake Cable - Rear, RH Parking Brake Cable - Rear, RH Removal and Installation 1. Release the parking brake cable tension. For additional information, refer to Parking Brake Cable Tension Release See: Procedures. 2. Remove the rear brake shoes. 3. Disconnect the parking brake cable from the cable connector and the equalizer bracket by compressing the cable conduit locking tabs. 4. Compress the retaining clip and detach the parking brake cable from the exhaust support bracket. 5. Remove the parking brake cable bracket bolt. - To install, tighten to 23 Nm (17 lb-ft). 6. Compress the rear parking brake cable conduit locking tabs and pull the cable assembly through the brake backing plate. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 4005 7. To install, reverse the removal procedure. Parking Brake Cable - Front Parking Brake Cable - Front Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parking brake control. For additional information, refer to Parking Brake Control See: Parking Brake Control/Service and Repair. 3. Remove the floor console. 4. Remove the driver side front seat. 5. Remove the 3 front parking brake cable bracket bolts. - To install, tighten to 23 Nm (17 lb-ft). 6. Disconnect the front parking brake cable from the RR parking brake cable connector by releasing the locking tab. 7. Disconnect the front parking brake cable conduit from the LR parking brake cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 4006 8. Release the front parking brake cable pass-through grommet from the vehicle underbody. 9. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair Parking Brake Control: Service and Repair Parking Brake Control Removal and Installation 1. Remove the front driver side door scuff plate and kick panel. 2. Release the parking brake cable tension. For additional information, refer to Parking Brake Cable Tension Release See: Parking Brake Cable/Service and Repair/Procedures. 3. Remove the parking brake release handle bolt. - To install, tighten to 10 Nm (89 lb-in). 4. Disconnect the parking brake warning indicator switch electrical connector and detach the harness pin-type retainer from the parking brake control cover. 5. Remove the 2 parking brake control bolts. - To install, tighten to 27 Nm (20 lb-ft). 6. Remove the 2 parking brake control nuts. - To install, tighten to 27 Nm (20 lb-ft). 7. Remove the parking brake control. - Disconnect the front parking brake cable. 8. NOTE: Make sure that the cable is in the groove on the control wheel prior to final tightening of fasteners. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair > Page 4010 To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Pedal: > 09-6-7 > Apr > 09 > Brakes - Park Brake Pedal Won't Fully Release Parking Brake Pedal: Customer Interest Brakes - Park Brake Pedal Won't Fully Release TSB 09-6-7 04/06/09 PARKING BRAKE PEDAL WILL NOT FULLY RETURN WHEN RELEASED - INDICATOR STAYS ON FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles, built on 10/1/2008 through and including 1/26/2009, may exhibit a parking brake indicator on the dash, due to the parking brake pedal not returning to the fully released position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify parking brake indicator is illuminated in the dash. 2. Pull the pedal up to the fully released position by hand. 3. If the indicator does not go out, this procedure does not apply. Refer to Workshop Manual (WSM), Section 206-00. 4. If the indicator does go out, replace the parking brake control assembly following WSM, Section 206-05. 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 090607A 2009 Escape, Mariner, 0.9 Hr. Escape Hybrid, Mariner Hybrid: Replace Parking Brake Control Assembly (Do Not Use With 2780A) DEALER CODING CONDITION BASIC PART NO. CODE 2780 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > 09-6-7 > Apr > 09 > Brakes - Park Brake Pedal Won't Fully Release Parking Brake Pedal: All Technical Service Bulletins Brakes - Park Brake Pedal Won't Fully Release TSB 09-6-7 04/06/09 PARKING BRAKE PEDAL WILL NOT FULLY RETURN WHEN RELEASED - INDICATOR STAYS ON FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles, built on 10/1/2008 through and including 1/26/2009, may exhibit a parking brake indicator on the dash, due to the parking brake pedal not returning to the fully released position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify parking brake indicator is illuminated in the dash. 2. Pull the pedal up to the fully released position by hand. 3. If the indicator does not go out, this procedure does not apply. Refer to Workshop Manual (WSM), Section 206-00. 4. If the indicator does go out, replace the parking brake control assembly following WSM, Section 206-05. 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 090607A 2009 Escape, Mariner, 0.9 Hr. Escape Hybrid, Mariner Hybrid: Replace Parking Brake Control Assembly (Do Not Use With 2780A) DEALER CODING CONDITION BASIC PART NO. CODE 2780 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4027 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4028 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Remove the parking brake release handle bolt. - To install, tighten to 10 Nm (89 lb-in). 2. Disconnect the warning indicator switch electrical connector. 3. Remove the bolt and warning indicator switch. - To install, tighten bolt to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations > Page 4033 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations > Page 4034 Brake Booster Vacuum Sensor: Service and Repair Brake Booster Vacuum Sensor - Hybrid Removal and Installation 1. Disconnect the brake booster vacuum sensor electrical connector. 2. Release the brake booster vacuum sensor retainer ring and remove the vacuum sensor. 3. To install, reverse the removal procedure. 4. Following the scan tool instructions, carry out the multi-calibration routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Locations > Simulator Cut-Off Valve Solenoid Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Locations > Simulator Cut-Off Valve Solenoid > Page 4040 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Diagrams > Simulator Cut-Off Valve Solenoid Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Diagrams > Simulator Cut-Off Valve Solenoid > Page 4043 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Diagrams > Page 4044 Vacuum Brake Booster: Description and Operation Brake Booster The power brake actuation system consists of the following components: - Brake booster - Brake booster check valve - Brake booster travel sensor (hybrid vehicles) - Brake booster vacuum sensor (hybrid vehicles) - Brake booster vacuum supply hose - Vacuum pump (hybrid vehicles) Conventional brake booster The brake booster uses engine vacuum from the intake manifold to create a partial vacuum inside the vacuum booster on both sides of the diaphragm. When the brake pedal is pressed, the booster rod opens a valve, allowing air to enter the booster on one side of the diaphragm while sealing off the opposite side. This increases pressure on that side of the diaphragm so that it helps push the rod, which in turn pushes the piston in the master cylinder. As the brake pedal is released, the valve seals off the outside air supply while opening the vacuum valve. This restores vacuum to both sides of the diaphragm, allowing everything to return to its original position. Active brake booster (hybrid vehicles) The active brake booster uses vacuum supplied by an engine mounted electronic vacuum pump and is similar to a conventional vacuum assist brake booster with the addition of a brake booster (vacuum) solenoid, a brake booster travel sensor and a vacuum sensor. If it is necessary to apply the vehicles friction brakes, the ABS module will send a signal to the brake booster solenoid that is proportional to the amount of brake torque requested. The booster solenoid will open to allow vacuum to draw the booster diaphragm and pushrod towards the master cylinder piston, building hydraulic pressure. The brake booster vacuum sensor is used by the ABS module to monitor vacuum maintained inside the brake booster. The brake booster travel sensor is used to monitor the performance of the brake booster. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Diagrams > Page 4045 Vacuum Brake Booster: Testing and Inspection Brake System Inspection Brake Booster (Hybrid Vehicles) 1. Inspect the brake booster for excessive corrosion or damage. Inspect the vacuum hoses for leaks and kinks. - Install a new brake booster if signs of excessive corrosion or damage is found. - Repair or replace vacuum hoses as necessary. 2. Check all electrical connections by wiggling connectors and flexing the wire harnesses. - Repair the connector, terminals or wire harness as needed. 3. Retrieve any ABS module DTCs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Diagrams > Page 4046 Vacuum Brake Booster: Service and Repair Brake Booster NOTE: Hybrid vehicle shown, gas vehicle similar. Removal and Installation All vehicles 1. NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp switch. This switch must be removed with the brake pedal in the at-rest position. The switch plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch. Remove the stoplamp switch. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Diagrams > Page 4047 2. NOTE: The booster push rod clevis-locking pin is a one-time use only part. Anytime the booster push rod clevis-locking pin is removed, a new booster push rod clevis-locking pin should be used. NOTE: Remove the clevis-locking pin by squeezing the locking tabs and pulling outward on the opposite end. Remove and discard the booster push rod clevis-locking pin. 3. Remove and discard the 4 brake booster nuts. - To install, tighten new nuts to 23 Nm (17 lb-ft). 4. Disconnect the vacuum hose/check valve assembly from the brake booster. Hybrid vehicles 5. Disconnect the vacuum pressure sensor, booster solenoid and the booster travel sensor electrical connectors. All vehicles 6. Remove and discard the 2 master cylinder nuts. - To install, tighten new nuts to 30 Nm (22 lb-ft). 7. NOTE: It is not necessary to disconnect the brake tube fittings. Carefully position the brake master cylinder assembly forward and remove the brake booster. 8. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch. This switch must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing this switch with the brake pedal in any other position will result in incorrect adjustment and may damage the switch. To install, reverse the removal procedure. Hybrid vehicles 9. Following the scan tool instructions, carry out the Multi-Calibration Routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams > Page 4051 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Brake Booster Travel Sensor - Hybrid Removal and Installation 1. Disconnect the brake booster travel sensor electrical connector. 2. Release the brake booster travel sensor retainer ring and remove the travel sensor. 3. To install, reverse the removal procedure. 4. Following the scan tool instructions, carry out the multi-calibration routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Locations > Page 4055 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Locations > Page 4056 Vacuum Pump: Service and Repair Brake Vacuum Pump Removal and Installation 1. Remove the Motor Electronics Cooling System (MECS) coolant pump bolts and position the pump and ground strap aside. - To install, tighten bolts to 20 Nm (177 lb-in). 2. Disconnect the vacuum pump electrical connector and detach the harness retainer from the vacuum pump bracket. 3. Remove the vacuum pump bracket nut. - To install, tighten to 25 Nm (18 lb-ft). 4. Remove the 2 vacuum pump bracket bolts. - To install, tighten the bolts to 25 Nm (18 lb-ft). - Position the vacuum pump to detach the vacuum hose and remove the vacuum pump. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump Relay, Brakes > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4064 Electronic Brake Control Module: Diagrams Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4065 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4066 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module NOTE: Non-hybrid vehicles shown, hybrid vehicles similar. Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: Do not swap ABS modules between vehicles, the ABS module and the Hydraulic Control Unit (HCU) are calibrated as an assembly. All vehicles 1. Remove the HCU. For additional information, refer to Hydraulic Control Unit (HCU) - Hybrid See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair. Non-hybrid vehicles Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4067 2. Remove the Hydraulic Control Unit (HCU) See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair. For additional information, refer to Hydraulic Control Unit (HCU) See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair. 3. Remove the jumper tube assembly bracket nut. - To install, tighten to 9 Nm (80 lb-in). 4. Disconnect the jumper tubes fittings from the HCU and remove the jumper tube assembly. - To install, tighten to 15 Nm (133 lb-in). All vehicles 5. Remove the 4 ABS module screws and the ABS module. - To install, tighten to 2 Nm (18 lb-in). 6. To install, reverse the removal procedure. 7. Configure the ABS module. 8. Calibrate the ABS module. - For non-hybrid vehicles, carry out the IVD Initialization sequence following the scan tool directions. - For hybrid vehicles, carry out the Multi-Calibration routine following the scan tool directions. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Vacuum Pump Relay, Brakes > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 4078 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 4079 Brake Booster Vacuum Sensor: Service and Repair Brake Booster Vacuum Sensor - Hybrid Removal and Installation 1. Disconnect the brake booster vacuum sensor electrical connector. 2. Release the brake booster vacuum sensor retainer ring and remove the vacuum sensor. 3. To install, reverse the removal procedure. 4. Following the scan tool instructions, carry out the multi-calibration routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4083 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 4087 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 4091 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4095 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4096 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Remove the parking brake release handle bolt. - To install, tighten to 10 Nm (89 lb-in). 2. Disconnect the warning indicator switch electrical connector. 3. Remove the bolt and warning indicator switch. - To install, tighten bolt to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 4100 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 4101 Traction Control Switch: Service and Repair Stability/Traction Control Switch Removal and Installation 1. Remove the lower Instrument Cluster (IC) center finish panel. 2. Depress the 2 tabs and remove the stability/traction control switch assembly. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams > Page 4105 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Brake Booster Travel Sensor - Hybrid Removal and Installation 1. Disconnect the brake booster travel sensor electrical connector. 2. Release the brake booster travel sensor retainer ring and remove the travel sensor. 3. To install, reverse the removal procedure. 4. Following the scan tool instructions, carry out the multi-calibration routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel Wheel Speed Sensor: Customer Interest ABS/TCS - Clicking Noise From Left Front Wheel TSB 09-5-5 03/23/09 LEFT FRONT ABS SENSOR CONTACTING TONE RING - VEHICLES BUILT 10/21/2008-10/31/2008 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built from 10/21/2008 to 10/31/2008 may exhibit a clicking or rubbing noise from the left front wheel speed sensor and/or exhibit ABS warning light activation. The left front wheel knuckle may have been machined incorrectly allowing the wheel speed sensor to contact the tone ring. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Measure the air gap between the left front wheel speed sensor and tone ring with a feeler gage. 2. If 0.02" (0.50 mm) or more - this procedure does not apply. Continue with normal diagnostics. 3. If less than 0.02" (0.5 mm) or evidence of contact - replace the left front wheel knuckle per Workshop Manual (WSM), Section 204-01 and the left front Wheel Speed Sensor per WSM, Section 206-09. Parts Block 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 090505A 2009 Escape Hybrid, 1.3 Hrs. Mariner Hybrid: Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Be Claimed With Operations B And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505A 2009 Escape, Mariner: 1.2 Hrs. Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel > Page 4114 Be Claimed With Operations B And/Or C (Do Not Use With 2001 B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505B 2009 Escape, Mariner, 0.6 Hr. Escape Hybrid, Mariner Hybrid: Check Caster, Camber And Toe In Can Be Claimed With Operation A And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505C 2009 Escape, Mariner, 0.2 Hr. Escape Hybrid, Mariner Hybrid: Correct Toe-In Can Be Claimed With Operation A And B (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 3K186 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel Wheel Speed Sensor: All Technical Service Bulletins ABS/TCS - Clicking Noise From Left Front Wheel TSB 09-5-5 03/23/09 LEFT FRONT ABS SENSOR CONTACTING TONE RING - VEHICLES BUILT 10/21/2008-10/31/2008 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built from 10/21/2008 to 10/31/2008 may exhibit a clicking or rubbing noise from the left front wheel speed sensor and/or exhibit ABS warning light activation. The left front wheel knuckle may have been machined incorrectly allowing the wheel speed sensor to contact the tone ring. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Measure the air gap between the left front wheel speed sensor and tone ring with a feeler gage. 2. If 0.02" (0.50 mm) or more - this procedure does not apply. Continue with normal diagnostics. 3. If less than 0.02" (0.5 mm) or evidence of contact - replace the left front wheel knuckle per Workshop Manual (WSM), Section 204-01 and the left front Wheel Speed Sensor per WSM, Section 206-09. Parts Block 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 090505A 2009 Escape Hybrid, 1.3 Hrs. Mariner Hybrid: Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Be Claimed With Operations B And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505A 2009 Escape, Mariner: 1.2 Hrs. Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel > Page 4120 Be Claimed With Operations B And/Or C (Do Not Use With 2001 B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505B 2009 Escape, Mariner, 0.6 Hr. Escape Hybrid, Mariner Hybrid: Check Caster, Camber And Toe In Can Be Claimed With Operation A And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505C 2009 Escape, Mariner, 0.2 Hr. Escape Hybrid, Mariner Hybrid: Correct Toe-In Can Be Claimed With Operation A And B (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 3K186 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 09-11-9 > Jun > 09 > Navigation Radio - Time Displays Twice In CD Mode Accessory Control Display: All Technical Service Bulletins Navigation Radio - Time Displays Twice In CD Mode TSB 09-11-9 06/15/09 NAVIGATION RADIO - WHEN ON IN CD MODE - TIME DISPLAYS TWICE IN THE FDIM FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape and Mariner vehicles equipped with Navigation radio, may exhibit a concern when turning on the audio unit in CD mode. The time will display twice in the Front Display lnter[ace Module (FDIM), both in the center and in the upper right hand corner. Normal operation should be the time displaying in the center of the FDIM when the Navigation unit is off and in the upper right hand corner of the FDIM when the Navigation unit is on. ACTION Reprogram the Front Display Interface Module (FDIM) module to the latest calibration using IDS release 61.04 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration and IDS patch files may also be obtained at the website. 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 091109A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Reprogram The FDIM (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 19C116 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4133 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4134 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4135 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 4138 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 4139 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 4140 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front Wheel Speed Sensor - Front Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector is located in the engine compartment. Disconnect the electrical connector. 3. NOTICE: Care must be taken during the removal of the grommet to prevent damage. If the grommet is damaged, a new sensor may need to be installed, even though the sensor is functional in all other aspects. Remove the grommet from the body. - When removing the body grommet, rotate the grommet into a position which allows the use of a small screwdriver to release the tabs on the underside of the body grommet. These 2 tabs are located at right angles to the sensor wire. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 4143 4. Remove the front wheel speed sensor harness from the retainer. 5. Remove the front wheel speed sensor harness-to-body bolt. - To install, tighten to 9 Nm (80 lb-in). 6. Remove the front wheel speed sensor harness-to-strut bracket bolt. - To install, tighten to 15 Nm (133 lb-in). 7. Remove the front wheel speed sensor bolt from the wheel knuckle. - To install, tighten to 9 Nm (80 lb-in). 8. NOTE: Clean off any foreign material that may have collected around the sensor before removal. Remove the front wheel speed sensor. 9. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 4144 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTICE: Care must be taken during the removal of the grommet to prevent damage. If the grommet is damaged, a new sensor may need to be installed, even though the sensor is functional in all other aspects. Remove the grommet from the body. - When removing the body grommet, rotate the grommet into a position which allows the use of a small screwdriver to release the tabs on the underside of the grommet. These 2 tabs are located at right angles to the sensor wire. 3. Disconnect the rear wheel speed sensor electrical connector. 4. Remove the rear wheel speed sensor harness from the harness retainer. 5. Remove the 3 rear wheel speed sensor harness bolts. - To install, tighten to 9 Nm (80 lb-in). 6. NOTE: Clean off any debris that may have collected around the sensor before removal. Remove the rear wheel speed sensor bolt from the wheel knuckle. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 4145 - To install, tighten to 9 Nm (80 lb-in). 7. Remove the rear wheel speed sensor. 8. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 4146 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring - Front Wheel Speed Sensor Ring - Front Removal 1. Remove the front halfshaft. 2. Using a suitable driver, remove the ABS wheel speed sensor ring. Installation Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 4147 1. Install the new ABS wheel speed sensor ring and the tools on the halfshaft as shown in the previous illustration. 2. Install the ABS wheel speed sensor ring to the dimension as shown. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 4148 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring - Rear Wheel Speed Sensor Ring - Rear Removal and Installation Front Wheel Drive (FWD) vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the rear wheel hub nut. - To install, tighten to 290 Nm (214 lb-ft). 3. Remove the sensor ring from the wheel hub. 4. To install, reverse the removal procedure. All-Wheel Drive (AWD) vehicles 5. The rear wheel speed sensor ring is integral to the rear axle halfshaft and cannot be repaired separately. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Removal and Installation NOTE: For non-functional ignition lock cylinders, the steering column lock module has to be replaced. 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 4158 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 4159 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair Battery Cable: Service and Repair Battery Cables - 2.5L Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 4164 Removal and Installation 1. Disconnect the battery. For additional information, refer to Battery Disconnect See: Service and Repair/Battery Disconnect. 2. Remove the air cleaner assembly. 3. Remove the generator B+ terminal nut. - To install, tighten to 12 Nm (106 lb-in). 4. Position the generator B+ terminal cable aside. 5. Disconnect the generator harness retainer. 6. Remove the starter solenoid terminal cover. 7. Remove the starter motor positive cable nut. - To install, tighten to 12 Nm (106 lb-in). 8. Remove the starter solenoid wire nut. - To install, tighten to 5 Nm (44 lb-in). 9. Position the starter motor terminals aside. 10. Remove the battery ground cable bolt. - To install, tighten to 25 Nm (18 lb-ft). 11. Position the battery ground cable aside. 12. Disconnect the pin-type retainer from the left rear of the engine. 13. Disconnect the pin-type retainer from the middle of the intake runners. 14. Disconnect the pin-type retainer from the front of the engine. 15. Disconnect the clip retainer from the right front of the engine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 4165 16. Disconnect the clip retainer from the left front of the engine. 17. Remove the body ground terminal bolt from the left fenderwell. - To install, tighten to 9 Nm (80 lb-in). 18. Open the Battery Junction Box (BJB) cover and remove the BJB terminal nut. - To install, tighten to 10 Nm (89 lb-in). 19. Position the BJB terminal aside. 20. Disconnect the BJB electrical connector. 21. Disconnect the retainers fastening the battery cables to the battery tray. 22. Remove the battery cables. 23. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 4171 Alternator: Mechanical Specifications General Specifications Torque Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4172 Alternator: Description and Operation Charging System The charging system is a negative ground system consisting of: - a generator. - an internal voltage regulator. - a charging system warning indicator. - a battery. - circuitry and cables. - a PCM. The generator is driven by the accessory drive belt. When the engine is started, the generator begins to generate AC which is internally converted to DC. The DC is controlled by the voltage regulator (located on the rear of the generator) and supplied to the battery. The PCM controls the voltage regulation set point, working with the generator internal voltage regulator over 2 control and communication circuits. The generator and voltage regulator: - supply current to the electrical system. - charge the battery. - adjust the generator field current to increase or decrease the generator output. - have a PCM-controlled warning lamp. - output is controlled by the PCM. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4173 Alternator: Service and Repair Generator - 2.5L Removal NOTICE: Do not allow any metal object to come in contact with the generator housing and internal diode cooling fins. A short circuit may result and burn out the diodes. Failure to follow this instruction may result in component damage. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery. 3. Remove the 5 bolts, 1 pushpin and the RH lower splash shield. 4. Rotate the front end accessory drive belt tensioner clockwise and position the accessory drive belt aside. 5. Remove the battery harness locator from the lower generator stud. 6. Remove the generator bolt. 7. Remove the 2 generator stud nuts. 8. Working from the top of the vehicle, press the locking tab to release the generator lower air duct from the generator and remove the lower air duct. 9. Position the generator B+ protective cover aside and remove the generator B+ terminal nut. 10. Position the generator B+ cable aside. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4174 11. Disconnect the generator electrical connector. 12. Remove the generator. 13. Remove the 3 screws and the generator upper air duct. Installation 1. Install the 3 screws and the generator upper air duct. - To install, tighten to 4 Nm (35 lb-in). 2. Working from the top of the vehicle, install the generator and the generator stud. 3. Install the 2 generator stud nuts hand-tight. 4. Install the generator B+ cable and install the generator B+ terminal nut. - To install, tighten to 12 Nm (106 lb-in). 5. Connect the generator electrical connector. 6. Position the generator B+ protective cover on the B+ terminal. 7. Working from under the vehicle, install the lower generator bolt hand-tight. 8. Tighten the 2 generator stud nuts. - To install, tighten to 47 Nm (35 lb-ft). 9. Install the lower generator air duct. 10. Tighten the generator bolt. - To install, tighten to 47 Nm (35 lb-ft). 11. Rotate the front end accessory drive belt tensioner clockwise and position the accessory drive belt onto the pulleys. 12. Install the 5 bolts, 1 pushpin and the RH lower splash shield. - To install, tighten to 8 Nm (71 lb-in). 13. Position the harness locator on the generator stud. 14. Connect the battery. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Removal and Installation NOTE: For non-functional ignition lock cylinders, the steering column lock module has to be replaced. 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment Key: Testing and Inspection Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment NOTE: This procedure is used when a customer needs keys programmed into the system and does not have 2 programmed ignition keys available. This procedure is also useful when a programmed ignition key(s) is lost or the ignition lock cylinder is replaced, and it is desired to erase key code(s) from the Passive Anti-Theft System (PATS) memory. NOTE: This procedure erases all programmed ignition keys from the vehicle memory and the vehicle does not start until 2 keys are programmed to the vehicle. This procedure also erases the Integrated Keyhead Transmitter (IKT) identification codes (TICs) from the Smart Junction Box (SJB), preventing the erased IKT from operating the Remote Keyless Entry (RKE) functions on the vehicle. NOTE: A minimum of 2 PATS keys must be programmed into the Instrument Cluster (IC) before the vehicle starts. NOTE: Two PATS encoded (contains a transponder) IKT keys (or standard PATS keys) with the correct mechanical cut must be available to carry out this procedure. One or both of them can be the customer's original keys. One or both of them can be an IKT or a standard PATS key. NOTE: If additional keys are to be programmed, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If the remaining keys are with the customer and are not available with the vehicle, instruct the customer to refer to the Owner's Literature for instructions on programming the remaining keys. In this case, the IC PID SPAREKEY must be enabled. NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. 1. Turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. From the scan tool menu select: IGNITION KEY CODE ERASE. Follow all Integrated Diagnostic System (IDS) screen instructions until the key erase procedure completes. The scan tool also instructs to program 2 keys to complete the process. 4. Turn the key to the OFF position and disconnect the scan tool (the key does not need to be removed at this time). 5. NOTE: The RKE data transfer takes place between the key and the IC first. After both keys are programmed into the IC, then the RKE data transfers from the IC to the Smart Junction Box (SJB). Until the final data transfer takes place into the SJB, the RKE functions does not operate. NOTE: IKT keys require a 6-second programming time frame for the RKE data transfer to take place, while standard PATS keys only require a minimum of 3 seconds. Turn the first PATS key to the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 7. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 8. The vehicle should now start with both ignition keys and the RKE transmitter portion of an IKT should function. 9. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the IC), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4184 Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4185 Key: Testing and Inspection Key Programming Switch State Control Key Programming Switch State Control NOTE: The spare key programming switch is a programmable switch which provides the capability to enable/disable the normal customer spare key programming procedure detailed in the Owner's Literature. It must read ENABLE if more than 2 keys need to be programmed into the Instrument Cluster (IC). For additional information, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. This programmable switch is provided as a convenience for rental company fleets or other fleet purchasers who may not want the spare key programming procedure available to the vehicle driver. NOTE: The spare key programming switch state can be viewed with the IC SPAREKEY PID. NOTE: If the SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the IC using Key Programming Using Two Programmed Keys. If the SPAREKEY PID reads DISABLED, the Key Programming Using Two Programmed Keys procedure does not function. This switch is set to ENABLE when the vehicle is built. This PID only affects the Key Programming Using Two Programmed Keys procedure. 1. Insert a programmed Passive Anti-Theft System (PATS) key (or Integrated Keyhead Transmitter (IKT)) into the ignition lock cylinder and turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. NOTE: The default setting on delivery of all new vehicles is ENABLED, when viewing the IC SPAREKEY PID. From the scan tool menu select: CUSTOMER SPARE KEY PROGRAMMING ENABLE and follow the Integrated Diagnostic System (IDS) on-screen instructions in order to complete the procedure. CUSTOMER SPARE KEY PROGRAMMING ENABLE - spare key programming procedure is accessible. - CUSTOMER SPARE KEY PROGRAMMING DISABLE - spare key programming procedure is not accessible. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4186 Key: Testing and Inspection Key Programming Using Two Programmed Keys Key Programming Using Two Programmed Keys NOTE: This procedure works only if 2 or more programmed ignition keys (they do not have to be Integrated Keyhead Transmitter (IKT) keys) are present. If 2 programmed Passive Anti-Theft System (PATS) keys are not available, refer to Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment. NOTE: The PID SPAREKEY must be enabled for this procedure to operate. If this PID is not enabled, refer to Key Programming Switch State Control See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Switch State Control, in order to enable the customer spare key programming PID. The PID SPAREKEY is set to ENABLE when the vehicle is built. NOTE: If the programming procedure is successful, the new key(s) starts the vehicle and the anti-theft indicator proves-out for approximately 3 seconds. If the programming procedure is not successful and the new key(s) does not start the engine, leave the key in the ON position for at least 3 seconds, then turn the key off. Repeat the key programming procedure from Step 1. If the failure repeats, refer to Anti-Theft See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection in the Diagnosis and Testing to review the DTCs and carry out the appropriate pinpoint tests. NOTE: A minimum of 2 PATS keys must be programmed into the Instrument Cluster (IC) before the vehicle will start. NOTE: If the vehicle is in unlimited key mode, this spare key programming procedure still functions. Any 2 keys that can start the vehicle can be used to program an additional unlimited key. NOTE: If additional keys are to be programmed, and the remaining keys are with the customer, or are not available, instruct the customer to refer to the Owner's Literature for instructions on programming the remaining keys. In this case, the PID SPAREKEY must be enabled. NOTE: If the steps are not carried out as outlined, the programming procedure ends. NOTE: Ignition keys must have a correct mechanical key cut for the vehicle and must be PATS encoded keys (contain a transponder). The key does not have to be an IKT key. NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. NOTE: A maximum of 8 ignition keys can be programmed to a PATS vehicle, of which up to 4 can be IKTs. If an attempt to program more than 4 IKTs occurs, the Smart Junction Box (SJB) and the IC set a memory full DTC (B1138), and the additional IKTs will not have any Remote Keyless Entry (RKE) function capability. If the vehicle is equipped with a message center, the IC displays the message INT KEY COULD NOT PROGRAM. The PATS portion of the additional key will function, but the RKE transmitter function will be inoperative. NOTE: When in the unlimited key mode (after the first 2 keys have been programmed to the vehicle), the N_KEYCODE PID will always read 2, no matter how many keys are programmed to the vehicle. 1. Insert a programmed ignition key (can be an IKT or a standard PATS key) into the ignition lock cylinder and turn the key from the OFF position to the ON position. 2. Leave the key in the ON position for 3 seconds, but not longer than 10 seconds. 3. Turn the key to the OFF position and remove the first key. 4. Within 10 seconds of turning the key to the OFF position, insert a second programmed ignition key (can be an IKT or a standard PATS key) into the ignition lock cylinder and turn the key from the OFF position to the ON position. 5. Leave the key in the ON position for 3 seconds, but not longer than 10 seconds. 6. Turn the key to the OFF position and remove the second key. 7. Within 20 seconds of turning the key to the OFF position, insert the unprogrammed ignition key (new PATS or IKT key) into the ignition lock cylinder and turn the key from the OFF position to the ON position. Leave the key in the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place, if programming an IKT key). 8. NOTE: The new key will now start the vehicle and will also operate the RKE functions, if there are 4 or fewer IKT keys programmed to the vehicle. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4187 Start the vehicle with the new key. If it is an IKT key, verify the RKE functions. 9. If additional programmed keys are desired, repeat Steps 1-7. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4188 Key: Testing and Inspection Spare Key Programming - Unlimited Key Mode Spare Key Programming - Unlimited Key Mode Enabling Unlimited Key Mode NOTE: Unlimited key mode is intended for use by those customers who need more than 8 keys for their vehicle. NOTE: If unlimited key mode is enabled, a maximum of 4 Integrated Keyhead Transmitter (IKT) keys can be programmed to the vehicle for Remote Keyless Entry (RKE) functionality. If more keys are required, they should be standard Passive Anti-Theft System (PATS) keys. If more than 4 IKT keys are programmed to the vehicle, the Smart Junction Box (SJB) and the Instrument Cluster (IC) will set DTC B1138 (memory full) and only 4 IKT keys will have RKE functionality, however, all of them will start the vehicle, if programmed correctly. NOTE: Before programming, the new key(s) must have the correct mechanical cut for the ignition lock cylinder. NOTE: The unlimited key mode is set up by creating a special, unique unlimited transponder security key code and programming this key code into all of the vehicle keys so they contain the same key code. NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2, no matter how many keys are programmed to the vehicle (after the first 2 keys have been programmed). 1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be programmed to all of their vehicles. All customer vehicles need to use the same number. Valid digits are 0-9 and the letters A-F. 2. NOTE: If the PID UNL_KEY_ID is not available, unlimited key mode is turned on and must be turned off before viewing the stored code. At this time, unlimited keys can be programmed to the vehicle. To view/change the stored code, follow the procedure for disabling the unlimited key mode below. Monitor the PID UNL_KEY_ID and compare its value against the code chosen in Step 1. It should not be the same key code. 3. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the Integrated Diagnostic System (IDS) on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 4. Once in security access, select: "program unlimited key code" and follow the IDS on-screen instructions. Enter the 8-digit code chosen by the customer in Step 1 of this procedure and follow the IDS on-screen instructions. 5. Select: "unlimited key mode ON" and follow the IDS on-screen instructions. 6. Select: "Ignition Key Code Erase" and follow the IDS on-screen instructions. 7. Disconnect the scan tool and turn the ignition switch to OFF. 8. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 9. Remove the first PATS key from the ignition lock cylinder. 10. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 11. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Disabling Unlimited Key Mode Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4189 NOTE: By disabling the unlimited key mode, the previous access code no longer operates the vehicle. 1. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 2. Select: "unlimited key mode OFF" and follow the IDS on-screen instructions. 3. Select: "Ignition Key Code Erase" and follow the IDS on-screen instructions. 4. Disconnect the scan tool and turn the ignition switch to OFF. 5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 6. Remove the first PATS key from the ignition lock cylinder. 7. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 8. NOTE: With the unlimited key mode turned off, a maximum of 8 keys can be programmed into the IC using the Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys procedure. The PID SPAREKEY must be enabled. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. The PID SPAREKEY must be enabled. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4190 Key: Testing and Inspection Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment NOTE: This procedure is used when a customer needs keys programmed into the system and does not have 2 programmed ignition keys available. This procedure is also useful when a programmed ignition key(s) is lost or the ignition lock cylinder is replaced, and it is desired to erase key code(s) from the Passive Anti-Theft System (PATS) memory. NOTE: This procedure erases all programmed ignition keys from the vehicle memory and the vehicle does not start until 2 keys are programmed to the vehicle. This procedure also erases the Integrated Keyhead Transmitter (IKT) identification codes (TICs) from the Smart Junction Box (SJB), preventing the erased IKT from operating the Remote Keyless Entry (RKE) functions on the vehicle. NOTE: A minimum of 2 PATS keys must be programmed into the Instrument Cluster (IC) before the vehicle starts. NOTE: Two PATS encoded (contains a transponder) IKT keys (or standard PATS keys) with the correct mechanical cut must be available to carry out this procedure. One or both of them can be the customer's original keys. One or both of them can be an IKT or a standard PATS key. NOTE: If additional keys are to be programmed, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If the remaining keys are with the customer and are not available with the vehicle, instruct the customer to refer to the Owner's Literature for instructions on programming the remaining keys. In this case, the IC PID SPAREKEY must be enabled. NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. 1. Turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. From the scan tool menu select: IGNITION KEY CODE ERASE. Follow all Integrated Diagnostic System (IDS) screen instructions until the key erase procedure completes. The scan tool also instructs to program 2 keys to complete the process. 4. Turn the key to the OFF position and disconnect the scan tool (the key does not need to be removed at this time). 5. NOTE: The RKE data transfer takes place between the key and the IC first. After both keys are programmed into the IC, then the RKE data transfers from the IC to the Smart Junction Box (SJB). Until the final data transfer takes place into the SJB, the RKE functions does not operate. NOTE: IKT keys require a 6-second programming time frame for the RKE data transfer to take place, while standard PATS keys only require a minimum of 3 seconds. Turn the first PATS key to the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 7. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 8. The vehicle should now start with both ignition keys and the RKE transmitter portion of an IKT should function. 9. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the IC), refer to Key Programming Using Two Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4191 Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Key Programming Switch State Control Key Programming Switch State Control NOTE: The spare key programming switch is a programmable switch which provides the capability to enable/disable the normal customer spare key programming procedure detailed in the Owner's Literature. It must read ENABLE if more than 2 keys need to be programmed into the Instrument Cluster (IC). For additional information, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. This programmable switch is provided as a convenience for rental company fleets or other fleet purchasers who may not want the spare key programming procedure available to the vehicle driver. NOTE: The spare key programming switch state can be viewed with the IC SPAREKEY PID. NOTE: If the SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the IC using Key Programming Using Two Programmed Keys. If the SPAREKEY PID reads DISABLED, the Key Programming Using Two Programmed Keys procedure does not function. This switch is set to ENABLE when the vehicle is built. This PID only affects the Key Programming Using Two Programmed Keys procedure. 1. Insert a programmed Passive Anti-Theft System (PATS) key (or Integrated Keyhead Transmitter (IKT)) into the ignition lock cylinder and turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. NOTE: The default setting on delivery of all new vehicles is ENABLED, when viewing the IC SPAREKEY PID. From the scan tool menu select: CUSTOMER SPARE KEY PROGRAMMING ENABLE and follow the Integrated Diagnostic System (IDS) on-screen instructions in order to complete the procedure. CUSTOMER SPARE KEY PROGRAMMING ENABLE - spare key programming procedure is accessible. - CUSTOMER SPARE KEY PROGRAMMING DISABLE - spare key programming procedure is not accessible. Key Programming Using Two Programmed Keys Key Programming Using Two Programmed Keys NOTE: This procedure works only if 2 or more programmed ignition keys (they do not have to be Integrated Keyhead Transmitter (IKT) keys) are present. If 2 programmed Passive Anti-Theft System (PATS) keys are not available, refer to Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment. NOTE: The PID SPAREKEY must be enabled for this procedure to operate. If this PID is not enabled, refer to Key Programming Switch State Control See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Switch State Control, in order to enable the customer spare key programming PID. The PID SPAREKEY is set to ENABLE when the vehicle is built. NOTE: If the programming procedure is successful, the new key(s) starts the vehicle and the anti-theft indicator proves-out for approximately 3 seconds. If the programming procedure is not successful and the new key(s) does not start the engine, leave the key in the ON position for at least 3 seconds, then turn the key off. Repeat the key programming procedure from Step 1. If the failure repeats, refer to Anti-Theft See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection in the Diagnosis and Testing to review the DTCs and carry out the appropriate pinpoint tests. NOTE: A minimum of 2 PATS keys must be programmed into the Instrument Cluster (IC) before the vehicle will start. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4192 NOTE: If the vehicle is in unlimited key mode, this spare key programming procedure still functions. Any 2 keys that can start the vehicle can be used to program an additional unlimited key. NOTE: If additional keys are to be programmed, and the remaining keys are with the customer, or are not available, instruct the customer to refer to the Owner's Literature for instructions on programming the remaining keys. In this case, the PID SPAREKEY must be enabled. NOTE: If the steps are not carried out as outlined, the programming procedure ends. NOTE: Ignition keys must have a correct mechanical key cut for the vehicle and must be PATS encoded keys (contain a transponder). The key does not have to be an IKT key. NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. NOTE: A maximum of 8 ignition keys can be programmed to a PATS vehicle, of which up to 4 can be IKTs. If an attempt to program more than 4 IKTs occurs, the Smart Junction Box (SJB) and the IC set a memory full DTC (B1138), and the additional IKTs will not have any Remote Keyless Entry (RKE) function capability. If the vehicle is equipped with a message center, the IC displays the message INT KEY COULD NOT PROGRAM. The PATS portion of the additional key will function, but the RKE transmitter function will be inoperative. NOTE: When in the unlimited key mode (after the first 2 keys have been programmed to the vehicle), the N_KEYCODE PID will always read 2, no matter how many keys are programmed to the vehicle. 1. Insert a programmed ignition key (can be an IKT or a standard PATS key) into the ignition lock cylinder and turn the key from the OFF position to the ON position. 2. Leave the key in the ON position for 3 seconds, but not longer than 10 seconds. 3. Turn the key to the OFF position and remove the first key. 4. Within 10 seconds of turning the key to the OFF position, insert a second programmed ignition key (can be an IKT or a standard PATS key) into the ignition lock cylinder and turn the key from the OFF position to the ON position. 5. Leave the key in the ON position for 3 seconds, but not longer than 10 seconds. 6. Turn the key to the OFF position and remove the second key. 7. Within 20 seconds of turning the key to the OFF position, insert the unprogrammed ignition key (new PATS or IKT key) into the ignition lock cylinder and turn the key from the OFF position to the ON position. Leave the key in the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place, if programming an IKT key). 8. NOTE: The new key will now start the vehicle and will also operate the RKE functions, if there are 4 or fewer IKT keys programmed to the vehicle. Start the vehicle with the new key. If it is an IKT key, verify the RKE functions. 9. If additional programmed keys are desired, repeat Steps 1-7. Spare Key Programming - Unlimited Key Mode Spare Key Programming - Unlimited Key Mode Enabling Unlimited Key Mode NOTE: Unlimited key mode is intended for use by those customers who need more than 8 keys for their vehicle. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4193 NOTE: If unlimited key mode is enabled, a maximum of 4 Integrated Keyhead Transmitter (IKT) keys can be programmed to the vehicle for Remote Keyless Entry (RKE) functionality. If more keys are required, they should be standard Passive Anti-Theft System (PATS) keys. If more than 4 IKT keys are programmed to the vehicle, the Smart Junction Box (SJB) and the Instrument Cluster (IC) will set DTC B1138 (memory full) and only 4 IKT keys will have RKE functionality, however, all of them will start the vehicle, if programmed correctly. NOTE: Before programming, the new key(s) must have the correct mechanical cut for the ignition lock cylinder. NOTE: The unlimited key mode is set up by creating a special, unique unlimited transponder security key code and programming this key code into all of the vehicle keys so they contain the same key code. NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2, no matter how many keys are programmed to the vehicle (after the first 2 keys have been programmed). 1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be programmed to all of their vehicles. All customer vehicles need to use the same number. Valid digits are 0-9 and the letters A-F. 2. NOTE: If the PID UNL_KEY_ID is not available, unlimited key mode is turned on and must be turned off before viewing the stored code. At this time, unlimited keys can be programmed to the vehicle. To view/change the stored code, follow the procedure for disabling the unlimited key mode below. Monitor the PID UNL_KEY_ID and compare its value against the code chosen in Step 1. It should not be the same key code. 3. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the Integrated Diagnostic System (IDS) on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 4. Once in security access, select: "program unlimited key code" and follow the IDS on-screen instructions. Enter the 8-digit code chosen by the customer in Step 1 of this procedure and follow the IDS on-screen instructions. 5. Select: "unlimited key mode ON" and follow the IDS on-screen instructions. 6. Select: "Ignition Key Code Erase" and follow the IDS on-screen instructions. 7. Disconnect the scan tool and turn the ignition switch to OFF. 8. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 9. Remove the first PATS key from the ignition lock cylinder. 10. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 11. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Disabling Unlimited Key Mode NOTE: By disabling the unlimited key mode, the previous access code no longer operates the vehicle. 1. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 2. Select: "unlimited key mode OFF" and follow the IDS on-screen instructions. 3. Select: "Ignition Key Code Erase" and follow the IDS on-screen instructions. 4. Disconnect the scan tool and turn the ignition switch to OFF. 5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 6. Remove the first PATS key from the ignition lock cylinder. 7. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4194 8. NOTE: With the unlimited key mode turned off, a maximum of 8 keys can be programmed into the IC using the Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys procedure. The PID SPAREKEY must be enabled. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. The PID SPAREKEY must be enabled. Spare Key Programming - Using Diagnostic Equipment Spare Key Programming - Using Diagnostic Equipment NOTE: This procedure is used when a customer needs to have an additional key programmed into the vehicle without erasing stored key codes, but does not have 2 programmed keys available. This procedure is also useful when attempting to determine if an ignition key is defective, as a new key can be installed without erasing keys or without having 2 programmed keys available. NOTE: Before programming, the new key must have the correct mechanical cut for the ignition lock cylinder. NOTE: If 8 keys are already programmed, this procedure does not allow any more ignition keys to be programmed. The number of keys that are programmed into the Passive Anti-Theft System (PATS) can be determined by viewing the N_KEYCODE PID. 1. Turn the new key to be programmed from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. NOTE: Make sure the selection made is "Program additional ignition key". If the "Ignition Key Code Erase" selection is made, all of the keys will be erased from the system. From the scan tool menu select: "Program additional ignition key". 4. Turn the key to the OFF position and disconnect the scan tool. 5. Start the vehicle with the new PATS key. The vehicle will now start with the new PATS key and also with the original PATS keys. If it is an IKT key, verify the RKE functions (if there are 4 or fewer IKT keys programmed). Passive Anti-Theft System (PATS) Parameter Reset Passive Anti-Theft System (PATS) Parameter Reset NOTE: When using the IDS, the Instrument Cluster (IC) and the Transmission Control Module (TCM) parameters are reset at the same time. NOTE: Once security access has been granted, multiple security access commands should be executed (if necessary) prior to exiting the command menu. This avoids an additional security access procedure and the associated 10 minute time delay. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4195 NOTE: Repair all Battery Control Module (BCM) DTCs and make sure the high voltage disconnect is installed before carrying out a parameter reset. A parameter reset will not occur if the High Voltage Traction Battery (HVTB) is not working correctly. 1. Turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. From the scan tool, select: Parameter Reset and follow the on-screen instructions. 4. NOTE: If the IC was replaced, follow Steps 4-9. If the IC and the TCM were replaced, follow Steps 4-9. If only the TCM was replaced, the procedure is completed. NOTE: If steps 4-9 are followed, 2 keys must be present. From the scan tool, select: Ignition Key Code Erase and follow the on-screen instructions. 5. Turn the key to the OFF position and disconnect the scan tool. 6. NOTE: Integrated Keyhead Transmitter (IKT) keys require a 6-second programming time frame for the Remote Keyless Entry (RKE) data transfer to take place, while standard PATS keys only require a minimum of 3 seconds. Turn the key to the ON position for a minimum of 6 seconds (if it is an IKT key). 7. Remove the key and cycle the second key to the ON position for a minimum of 6 seconds (if it is an IKT key). 8. Both keys will now start the vehicle and will also operate the RKE functions of the vehicle (if they are IKT keys). 9. NOTE: The RKE data transfer will take place between the key and the IC first. After both keys are programmed into the IC, the RKE data will transfer from the IC to the Smart Junction Box (SJB). Until the final data transfer takes place into the SJB, the RKE functions will not operate. If more keys are required to be programmed, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 4199 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 4200 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > General Specifications Starter Motor: Specifications General Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > General Specifications > Page 4205 Starter Motor: Specifications Torque Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4206 Starter Motor: Service and Repair Starter Motor - 2.5L Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the 5 bolts, the pin-type retainer (not shown) and the RH splash shield. - To install, tighten to 9 Nm (80 lb-in). 4. Remove the starter solenoid wire nut. - To install, tighten to 5 Nm (44 lb-in). 5. Remove the starter solenoid battery cable nut and disconnect the starter motor solenoid terminal cover and cables. - To install, tighten to 12 Nm (106 lb-in). 6. Remove the ground wire nut and position aside the ground wire. - To install, tighten to 25 Nm (18 lb-ft). 7. Remove the 2 stud bolts and the starter motor. - To install, tighten to 35 Nm (26 lb-ft). 8. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Specifications > General Specifications Auxiliary Power Outlet: Specifications General Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Specifications > General Specifications > Page 4212 Auxiliary Power Outlet: Specifications Torque Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Console Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Console > Page 4215 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4216 Auxiliary Power Outlet: Description and Operation High-Voltage Converter/Inverter DC/AC Inverter and AC Power Point The DC/AC inverter converts 12 volts DC to 110 volts AC to power a device that uses AC current with a rating of less than 150 watts. DC/DC Converter The DC/DC converter is a liquid-cooled component that converts high voltage (216-397 volts) DC power to low voltage (12 volts) DC power while maintaining electrical isolation between the 2 DC power systems. The converter steps down the high voltage to 12 volts, providing power to the vehicle low voltage battery systems. The PCM controls the operation of the DC/DC converter through an enable input from the PCM to the DC/DC converter. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Auxiliary Power Outlet: Initial Inspection and Diagnostic Overview Special Tools Used With Diagnostics High-Voltage Converter/Inverter Principles Of Operation High-Voltage Converter/Inverter Principles of Operation DC/AC Inverter and AC Power Point The DC/AC inverter converts 12 volts DC to 110 volts AC to power a device that uses AC current with a rating of less than 150 watts. The 110 volts AC created by the inverter will measure differently than a conventional AC outlet (utility-generated) with some multi-meters. The power point will automatically shut off if the load exceeds 150 watts. This prevents damage to the inverter or load. The inverter supplies 110 volts AC power only when the key is in the ON/START position. This reduces the draw on the 12-volt system when the vehicle is not running. The DC/AC inverter outlet (AC power point) is equipped with a green LED that indicates the system integrity. The green LED illuminates continuously when the key is in the ON/START position and the system is operating normally. The green LED flashes constantly if the key is in the ON/START position and a fault is detected. Short circuits, overloads or overheating of the inverter will cause the green LED to flash and the power to be cut off to the outlet. If the LED is flashing, the problem must be corrected (short circuit or excessive load). If the inverter is overheated, it must be allowed time to cool off (without the load connected). Refer to Owner's Literature for a list of appropriate electrical loads/devices that can be used. DC/DC Converter The DC/DC converter is a liquid-cooled component that converts high voltage (216-397 volts) DC power to low voltage (12 volts) DC power, while maintaining electrical isolation between the 2 DC power systems. The converter steps down the high voltage to 12 volts, providing power to the vehicle low voltage battery systems. The PCM controls the operation of the DC/DC converter through an enable input from the PCM to the DC/DC converter. Inspection And Verification High-Voltage Converter/Inverter Inspection and Verification WARNING: When servicing the high-voltage system, establish a buffer zone per the specified procedure. Failure to follow this instruction may result in serious personal injury or death. WARNING: Depower the high-voltage traction battery (HVTB) before carrying out any removal or installation procedures affecting the high-voltage battery system. Failure to follow this instruction may result in serious personal injury or death. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4219 WARNING: Wear high-voltage insulated safety gloves and a face shield when working with high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate safety and protection rating. Inspect the gloves before use and always wear them with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to follow these instructions may result in serious personal injury or death. WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious personal injury or death. 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures 5. Clear the continuous DTCs and carry out the Self Test Diagnostics for the PCM. 6. If the DTCs retrieved are related to this concern, go to the DTC Chart. For all other DTCs, refer to Body Control Systems. See: Diagnostic Trouble Code Descriptions Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4220 Auxiliary Power Outlet: Diagnostic Trouble Code Descriptions High-Voltage Converter/Inverter P1A0C Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4221 Auxiliary Power Outlet: Symptom Related Diagnostic Procedures High-Voltage Converter/Inverter Symptom Chart Symptom Chart Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4222 Auxiliary Power Outlet: Pinpoint Tests Pinpoint Test A: The DC/AC Inverter Does Not Operate Correctly - No Power At The AC Power Point High-Voltage Converter/Inverter Pinpoint Tests Pinpoint Test A: The DC/AC Inverter Does Not Operate Correctly - No Power at the AC Power Point Refer to Wiring Diagram Set 12 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Charging System for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The DC/AC inverter receives 12 volts DC on circuits SBP04 (GN/RD) and CBP35 (YE/GY) and is grounded on circuit GD182 (BK/GY). The incoming DC power is internally converted to 60 cycle 110 volts AC power that is output to the AC power point on circuits HYA01 (OG/GN) (power) and HYA02 (OG/WH) (neutral). NOTE: The electrical device that is powered by the AC power point must not exceed 150 watts. NOTE: If the green LED is flashing, the AC power point may be overloaded, overheated or shorted. Unplug the electrical device from the AC power point and cycle the key. Refer to the Owner's Literature to determine if the electrical device is appropriate for the AC power point. This pinpoint test is intended to diagnose the following: - Fuses - Circuits - DC/AC inverter - AC power point PINPOINT TEST A: THE DC/AC INVERTER DOES NOT OPERATE CORRECTLY - NO POWER AT THE AC POWER POINT NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. ------------------------------------------------- A1 CHECK CIRCUITS SBP04 (GN/RD) AND CBP35 (YE/GY) FOR VOLTAGE - Ignition OFF. - Disconnect: DC/AC Inverter C2293a. - Ignition ON. - Measure the voltage between DC/AC inverter C2293a-1, circuit SBP04 (GN/RD), harness side and ground. - Measure the voltage between DC/AC inverter C2293a-3, circuit CBP35 (YE/GY), harness side and ground - Are the voltages greater than 10 volts? Yes GO to A2. No CHECK the Smart Junction Box (SJB) fuses 1 (30A) and 35 (10A). If OK, REPAIR the circuit(s). TEST the system for normal operation. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4223 A2 CHECK CIRCUIT GD182 (BK/GY) FOR AN OPEN - Ignition OFF. - Measure the resistance between DC/AC inverter C2293a-6, circuit GD182 (BK/GY), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to A3. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- A3 CHECK CIRCUITS HYA01 (OG/GN) AND HYA02 (OG/WH) FOR AN OPEN - Disconnect: AC Power Point C2292. - Disconnect: DC/AC Inverter C2293b. - Measure the resistance between DC/AC inverter C2293b-1, circuit HYA01 (OG/GN), harness side and AC power point C2292-1 circuit HYA01 (OG/GN), harness side; - Measure the resistance between DC/AC inverter C2293b-5, circuit HYA02 (OG/WH), harness side and AC power point C2292-3 circuit HYA02 (OG/WH), harness side. - Are the resistances less than 5 ohms? Yes GO to A4. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- A4 CHECK THE AC POWER POINT FOR AN OPEN - Measure the resistance between AC power point C2292-1, component side and AC power point C2292-2. - Measure the resistance between AC power point C2292-3, component side and AC power point C2292-1. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4224 - Are the resistances less than 5 ohms? Yes INSTALL a new DC/AC inverter. REFER to Direct Current/Alternating Current (DC/AC) Inverter See: Service and Repair/High Voltage Converter/Inverter/Direct Current/Alternating Current (DC/AC) Inverter. TEST the system for normal operation. No INSTALL a new AC power point. REFER to Alternating Current (AC) Powerpoint See: Service and Repair/High Voltage Converter/Inverter/Alternating Current (AC) Powerpoint. TEST the system for normal operation. ------------------------------------------------Pinpoint Test B: The DC/AC Inverter Does Not Operate Correctly - The AC Power Point LED Indicator Is Never On High-Voltage Converter/Inverter Pinpoint Tests Pinpoint Test B: The DC/AC Inverter Does Not Operate Correctly - The AC Power Point LED Indicator is Never On Refer to Wiring Diagram Set 12 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Charging System for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The DC/AC inverter receives 12 volts DC on circuits SBP04 (GN/RD) and CBP35 (YE/GY) and is grounded on circuit GD182 (BK/GY). The incoming DC power is internally converted to 60 cycle 110 volts AC power that is output to the AC power point on circuits HYA01 (OG/GN) (power) and HYA02 (OG/WH) (neutral). If a fault in the system is detected, the LED flashes when the key is in the ON position. The LED continuously illuminates if the system is operating correctly when the key is in the ON position. This pinpoint test is intended to diagnose the following: - Fuses - Circuits - DC/AC inverter - AC power point PINPOINT TEST B: THE DC/AC INVERTER DOES NOT OPERATE CORRECTLY - THE AC POWER POINT LED INDICATOR IS NEVER ON NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. ------------------------------------------------- B1 CHECK CIRCUIT CBP35 (YE/GY) FOR VOLTAGE - Ignition OFF. - Disconnect: DC/AC Inverter C2293a. - Ignition ON. - Measure the voltage between DC/AC inverter C2293a-3, circuit CBP35 (YE/GY), harness side and ground - Is the voltage greater than 10 volts? Yes Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4225 GO to B2. No CHECK the Smart Junction Box (SJB) fuse 35 (10A). If OK, REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- B2 CHECK CIRCUIT GD182 (BK/GY) FOR AN OPEN - Ignition OFF. - Measure the resistance between DC/AC inverter C2293a-6, circuit GD182 (BK/GY), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to B3. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- B3 CHECK CIRCUITS LYA03 (YE/VT) AND RYA03 (BU/BN) FOR AN OPEN - Disconnect: DC/AC Inverter C2293b. - Disconnect: AC Power Point C2292. - Measure the resistance between DC/AC inverter C2293b-9, circuit LYA03 (YE/VT), harness side and AC power point C2292-6 circuit LYA03 (YE/VT), harness side; and between DC/AC inverter C2293b-8, circuit RYA03 (BU/BN), harness side and AC power point C2292-5 circuit RYA03 (BU/BN), harness side. - Are the resistances less than 5 ohms? Yes GO to B4. No REPAIR the circuit(s). TEST the system for normal operation. ------------------------------------------------- B4 CHECK THE AC POWER POINT LED - Test the diode between AC power point C2292-5, component side and AC power point C2292-6, component side in both directions. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4226 - Is the resistance greater than 10,000 ohms in one direction and between 10-20 ohms in the opposite direction? Yes INSTALL a new DC/AC inverter. REFER to Direct Current/Alternating Current (DC/AC) Inverter See: Service and Repair/High Voltage Converter/Inverter/Direct Current/Alternating Current (DC/AC) Inverter. TEST the system for normal operation. No INSTALL a new AC power point. REFER to Alternating Current (AC) Powerpoint See: Service and Repair/High Voltage Converter/Inverter/Alternating Current (AC) Powerpoint. TEST the system for normal operation. ------------------------------------------------Pinpoint Test C: The DC/DC Converter Does Not Operate Correctly High-Voltage Converter/Inverter Pinpoint Tests Pinpoint Test C: The DC/DC Converter Does Not Operate Correctly Refer to Wiring Diagram Set 12 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Charging System for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The DC/DC converter is a liquid-cooled component that converts high voltage (216-397 volts) DC power to low voltage (12 volts) DC power while maintaining electrical isolation between the 2 DC power systems. The converter steps down the high voltage to 12 volts, providing power to the vehicle low voltage battery system. The PCM controls the operation of the DC/DC converter through an enable input from the PCM to the DC/DC converter. This pinpoint test is intended to diagnose the following: - PCM - 12-volt battery - Battery cables - DC/DC converter PINPOINT TEST C: THE DC/DC CONVERTER DOES NOT OPERATE CORRECTLY ------------------------------------------------- C1 CHECK THE PCM FOR DTCs WARNING: When servicing the high-voltage system, establish a buffer zone per the specified procedure. Failure to follow this instruction may result in serious personal injury or death. WARNING: Depower the high-voltage traction battery (HVTB) before carrying out any removal or installation procedures affecting the high-voltage battery system. Failure to follow this instruction may result in serious personal injury or death. WARNING: Wear high-voltage insulated safety gloves and a face shield when working with high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate safety and protection rating. Inspect the gloves before use and always wear them with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to follow these instructions may result in serious personal injury or death. WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious personal injury or death. - Enter the following diagnostic mode on the scan tool: Self Test/Retrieve and Record On-Demand and Continuous Memory DTCs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4227 - Are any PCM DTCs present? Yes For DTC P1A0C only, GO to C2. For all other DTCs, REFER to Computers and Control Systems Information. No GO to C2. ------------------------------------------------- C2 CHECK THE INTEGRITY OF THE 12-VOLT BATTERY - Ignition OFF. - Carry out the Battery - Condition Test to determine if the battery can hold a charge and is OK for use. Refer to Battery. See: Battery/Testing and Inspection/Pinpoint Tests - Did the battery pass the condition test? Yes GO to C3. No INSTALL a new 12-volt battery. ------------------------------------------------- C3 CHECK FOR CURRENT DRAINS - Carry out the Battery - Drain Test. Refer to the Diagnosis and Testing in Battery. See: Battery/Testing and Inspection/Component Tests and General Diagnostics See: Battery/Testing and Inspection - Are any circuits causing excessive current drains? Yes REPAIR as necessary. TEST the system for normal operation. No GO to C4. ------------------------------------------------- C4 CHECK THE VOLTAGE TO THE 12-VOLT BATTERY - Start the engine. - NOTE: The vehicle will start when the ignition switch is turned to the START position, but after a short period of time (approximately 2 minutes) the engine may shut down with the ignition switch still in the ON position. The DC/DC converter will output a normal charging rate with the engine running or not, but the engine MUST have run at least once. The state of charge of the High Voltage Traction Battery (HVTB) will have a direct affect on the length of engine running time. - With the engine running (ignition switch ON, engine must have run at least once), monitor the voltage at the 12-volt battery. - Is the voltage between 13.2-16.0 volts? Yes The system is operating correctly at this time. TEST the system for normal operation. No GO to C5. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4228 ------------------------------------------------- C5 CHECK THE POSITIVE 12-VOLT CABLE - With the engine running (ignition switch ON, engine must have run at least once), headlights on high beam and the heater blower fan on high, measure the voltage drop between DC/DC converter positive C1457c, post side and 12-volt battery positive C1100a, post side. - Is the voltage drop less than 0.75 volt? Yes GO to C6. No REPAIR or INSTALL a new 12-volt battery cable assembly as necessary. TEST the system for normal operation. ------------------------------------------------- C6 CHECK THE NEGATIVE 12-VOLT CABLE - With the engine running (ignition switch ON, engine must have run at least once), headlights on high beam and the heater blower fan on high, measure the voltage drop between DC/DC converter negative C1457b, post side and DC/DC converter ground G105, ground bolt side. - Is the voltage drop less than 0.25 volt? Yes GO to C7. No REPAIR or INSTALL a new 12-volt battery cable assembly as necessary. TEST the system for normal operation. ------------------------------------------------- C7 CHECK FOR CORRECT DC/DC CONVERTER OPERATION - Disconnect all of the DC/DC converter connectors. - Check for: corrosion. - pushed-out pins. - Connect all of the DC/DC converter connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new DC/DC converter. REFER to Direct Current/Direct Current (DC/DC) Converter See: Hybrid Drive Systems/Power Control System/Voltage Converter/Service and Repair/Direct Current/Direct Current (DC/DC) Converter. TEST the system for normal operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4229 No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. TEST the system for normal operation. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > High Voltage Converter/Inverter Auxiliary Power Outlet: Service and Repair High Voltage Converter/Inverter Alternating Current (AC) Powerpoint Alternating Current (AC) Powerpoint Removal and Installation 1. Disconnect the 12-volt battery. 2. Remove the console trim insert. 3. Disconnect the electrical connector and remove the AC power point. 4. To install, reverse the removal procedure. Direct Current/Alternating Current (DC/AC) Inverter Direct Current/Alternating Current (DC/AC) Inverter Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > High Voltage Converter/Inverter > Page 4232 Removal and Installation 1. Disconnect the 12-volt battery. 2. Remove the lower LH center instrument panel finish panel. 3. Disconnect the electrical connectors from the DC/AC inverter. 4. Remove the 2 DC/AC inverter nuts. - To install, tighten to 9 Nm (80 lb-in). 5. Remove the DC/AC inverter bolt. - To install, tighten 11 Nm (97 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > High Voltage Converter/Inverter > Page 4233 6. Remove the DC/AC inverter. 7. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > High Voltage Converter/Inverter > Page 4234 Auxiliary Power Outlet: Service and Repair Power Point Power Point Removal NOTE: Power point cover may differ depending on location. 1. Open the power point cover. 2. Install the Power Point Socket Remover in one of the power point socket slots. 3. Position the Power Point Socket Remover so that it engages in the adjacent slot. 4. Using the Power Point Socket Remover, pull the power point socket out of the retainer. 5. Disconnect the electrical connector. Installation 1. Connect the electrical connector. 2. Slide the power point socket into the retainer. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel Fuse: Locations Passenger Compartment Fuse Panel Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4242 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4243 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4244 Fuse: Locations Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4245 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4246 Fuse: Locations Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4247 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4248 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4249 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4250 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4251 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4252 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4253 Fuse: Locations Power Distribution Box Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4254 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel Fuse: Application and ID Passenger Compartment Fuse Panel Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4257 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4258 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4259 Fuse: Application and ID Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4260 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4261 Fuse: Application and ID Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4262 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4263 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4264 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4265 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4266 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4267 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4268 Fuse: Application and ID Power Distribution Box Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4269 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 4274 Fuse Block: Locations Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 4275 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 4276 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4279 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4280 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4281 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4282 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4283 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4284 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4285 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4286 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4287 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4288 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4289 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4290 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4291 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4292 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4293 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4294 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4295 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4296 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4297 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4298 Fuse Block: Connector Views Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4299 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4300 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4301 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4302 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4303 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4304 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 4308 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4313 Multiple Junction Connector: Diagrams C210 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4314 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4315 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4316 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4317 Multiple Junction Connector: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4318 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4319 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4320 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4321 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4322 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4323 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4324 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4325 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4326 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4327 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4328 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4329 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4330 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4331 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4332 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4333 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4334 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4335 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4336 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4337 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4338 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4339 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4340 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4341 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4342 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4343 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4344 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair Power Distribution Module: Service and Repair Smart Junction Box (SJB) Removal NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new Smart Junction Box (SJB) after installation. In the event that As-Built data is required (SJB will not communicate), all Remote Keyless Entry (RKE) devices must be programmed to the new SJB. A minimum of 2 RKE devices are necessary to complete the configuration and turn off the flashing interior lights. The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. NOTE: The steps included in the SJB removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered in a manufacturing mode with 7 pre-set DTCs related to the TPMS. To clear the DTCs, successful configuration of the SJB must occur, followed by successful TPMS sensor training, and a successful self-test. The DTCs are as follows: - B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) - B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is necessary only if the SJB is being replaced. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 4348 Upload the module configuration information from the SJB. 2. Remove the transmission selector lever bezel from the floor console finish panel. 3. Remove the floor console SJB cover. 4. Remove the floor console finish panel. 5. Disconnect the 7 electrical connectors. 6. Remove the 2 bolts and the SJB. Installation 1. Install the SJB. - Install the 2 bolts. - Connect the 7 electrical connectors. 2. Install the transmission selector lever bezel into the floor console finish panel. 3. NOTE: If the SJB was not replaced, this is the last step that is necessary. Install the floor console SJB cover. 4. NOTE: When successful, this step provides the calibration necessary for the SJB operation and clears DTCs B2477 and B106D. The clearing of these DTCs indicates the calibration data has been successfully downloaded to the new SJB. NOTE: The RKE transmitter portion of the Integrated Keyhead Transmitter (IKT) key is automatically transferred during Programmable Module Installation (PMI). Passive Anti-Theft System (PATS) programming is not necessary. If As-Built data is required during PMI, all remote transmitters (IKT or fob) must be programmed to the new SJB. Cycling the ignition to run for 6 seconds with each IKT will program the RKE function of the IKT key. NOTE: DTC B2276 may be set, indicating there are less than 2 transmitters programmed to the SJB. 5. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the SJB has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 6. NOTE: DTC C2780 will not clear if any other DTCs are present in the SJB. When successful, this step will clear DTC C2780. Carry out the SJB self-test (must include an on-demand self-test) and then repeat the self-test to confirm all DTCs have been cleared. 7. Rotate the instrument panel dimmer switch from the full dim position to the dome ON position. This will make sure that all displays are visible under all lighting conditions. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 4356 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair Power Distribution Module: Service and Repair Smart Junction Box (SJB) Removal NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new Smart Junction Box (SJB) after installation. In the event that As-Built data is required (SJB will not communicate), all Remote Keyless Entry (RKE) devices must be programmed to the new SJB. A minimum of 2 RKE devices are necessary to complete the configuration and turn off the flashing interior lights. The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. NOTE: The steps included in the SJB removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered in a manufacturing mode with 7 pre-set DTCs related to the TPMS. To clear the DTCs, successful configuration of the SJB must occur, followed by successful TPMS sensor training, and a successful self-test. The DTCs are as follows: - B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) - B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is necessary only if the SJB is being replaced. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 4360 Upload the module configuration information from the SJB. 2. Remove the transmission selector lever bezel from the floor console finish panel. 3. Remove the floor console SJB cover. 4. Remove the floor console finish panel. 5. Disconnect the 7 electrical connectors. 6. Remove the 2 bolts and the SJB. Installation 1. Install the SJB. - Install the 2 bolts. - Connect the 7 electrical connectors. 2. Install the transmission selector lever bezel into the floor console finish panel. 3. NOTE: If the SJB was not replaced, this is the last step that is necessary. Install the floor console SJB cover. 4. NOTE: When successful, this step provides the calibration necessary for the SJB operation and clears DTCs B2477 and B106D. The clearing of these DTCs indicates the calibration data has been successfully downloaded to the new SJB. NOTE: The RKE transmitter portion of the Integrated Keyhead Transmitter (IKT) key is automatically transferred during Programmable Module Installation (PMI). Passive Anti-Theft System (PATS) programming is not necessary. If As-Built data is required during PMI, all remote transmitters (IKT or fob) must be programmed to the new SJB. Cycling the ignition to run for 6 seconds with each IKT will program the RKE function of the IKT key. NOTE: DTC B2276 may be set, indicating there are less than 2 transmitters programmed to the SJB. 5. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the SJB has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 6. NOTE: DTC C2780 will not clear if any other DTCs are present in the SJB. When successful, this step will clear DTC C2780. Carry out the SJB self-test (must include an on-demand self-test) and then repeat the self-test to confirm all DTCs have been cleared. 7. Rotate the instrument panel dimmer switch from the full dim position to the dome ON position. This will make sure that all displays are visible under all lighting conditions. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4368 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4369 Relay Box: Locations Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4370 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4371 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4374 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4375 Relay Box: Diagrams Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4376 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4377 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4378 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4379 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4380 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 (BJB) Relay Box: Application and ID Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 (BJB) > Page 4383 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 (BJB) > Page 4384 Relay Box: Application and ID Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 (BJB) > Page 4385 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4390 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4391 Relay Box: Locations Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4392 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4393 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4396 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4397 Relay Box: Diagrams Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4398 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4399 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4400 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4401 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4402 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) Relay Box: Application and ID Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 4405 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 4406 Relay Box: Application and ID Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 4407 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Specifications > General Specifications Auxiliary Power Outlet: Specifications General Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Specifications > General Specifications > Page 4413 Auxiliary Power Outlet: Specifications Torque Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Console Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Console > Page 4416 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4417 Auxiliary Power Outlet: Description and Operation High-Voltage Converter/Inverter DC/AC Inverter and AC Power Point The DC/AC inverter converts 12 volts DC to 110 volts AC to power a device that uses AC current with a rating of less than 150 watts. DC/DC Converter The DC/DC converter is a liquid-cooled component that converts high voltage (216-397 volts) DC power to low voltage (12 volts) DC power while maintaining electrical isolation between the 2 DC power systems. The converter steps down the high voltage to 12 volts, providing power to the vehicle low voltage battery systems. The PCM controls the operation of the DC/DC converter through an enable input from the PCM to the DC/DC converter. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Auxiliary Power Outlet: Initial Inspection and Diagnostic Overview Special Tools Used With Diagnostics High-Voltage Converter/Inverter Principles Of Operation High-Voltage Converter/Inverter Principles of Operation DC/AC Inverter and AC Power Point The DC/AC inverter converts 12 volts DC to 110 volts AC to power a device that uses AC current with a rating of less than 150 watts. The 110 volts AC created by the inverter will measure differently than a conventional AC outlet (utility-generated) with some multi-meters. The power point will automatically shut off if the load exceeds 150 watts. This prevents damage to the inverter or load. The inverter supplies 110 volts AC power only when the key is in the ON/START position. This reduces the draw on the 12-volt system when the vehicle is not running. The DC/AC inverter outlet (AC power point) is equipped with a green LED that indicates the system integrity. The green LED illuminates continuously when the key is in the ON/START position and the system is operating normally. The green LED flashes constantly if the key is in the ON/START position and a fault is detected. Short circuits, overloads or overheating of the inverter will cause the green LED to flash and the power to be cut off to the outlet. If the LED is flashing, the problem must be corrected (short circuit or excessive load). If the inverter is overheated, it must be allowed time to cool off (without the load connected). Refer to Owner's Literature for a list of appropriate electrical loads/devices that can be used. DC/DC Converter The DC/DC converter is a liquid-cooled component that converts high voltage (216-397 volts) DC power to low voltage (12 volts) DC power, while maintaining electrical isolation between the 2 DC power systems. The converter steps down the high voltage to 12 volts, providing power to the vehicle low voltage battery systems. The PCM controls the operation of the DC/DC converter through an enable input from the PCM to the DC/DC converter. Inspection And Verification High-Voltage Converter/Inverter Inspection and Verification WARNING: When servicing the high-voltage system, establish a buffer zone per the specified procedure. Failure to follow this instruction may result in serious personal injury or death. WARNING: Depower the high-voltage traction battery (HVTB) before carrying out any removal or installation procedures affecting the high-voltage battery system. Failure to follow this instruction may result in serious personal injury or death. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4420 WARNING: Wear high-voltage insulated safety gloves and a face shield when working with high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate safety and protection rating. Inspect the gloves before use and always wear them with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to follow these instructions may result in serious personal injury or death. WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious personal injury or death. 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures 5. Clear the continuous DTCs and carry out the Self Test Diagnostics for the PCM. 6. If the DTCs retrieved are related to this concern, go to the DTC Chart. For all other DTCs, refer to Body Control Systems. See: Diagnostic Trouble Code Descriptions Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4421 Auxiliary Power Outlet: Diagnostic Trouble Code Descriptions High-Voltage Converter/Inverter P1A0C Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4422 Auxiliary Power Outlet: Symptom Related Diagnostic Procedures High-Voltage Converter/Inverter Symptom Chart Symptom Chart Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4423 Auxiliary Power Outlet: Pinpoint Tests Pinpoint Test A: The DC/AC Inverter Does Not Operate Correctly - No Power At The AC Power Point High-Voltage Converter/Inverter Pinpoint Tests Pinpoint Test A: The DC/AC Inverter Does Not Operate Correctly - No Power at the AC Power Point Refer to Wiring Diagram Set 12 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Charging System for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The DC/AC inverter receives 12 volts DC on circuits SBP04 (GN/RD) and CBP35 (YE/GY) and is grounded on circuit GD182 (BK/GY). The incoming DC power is internally converted to 60 cycle 110 volts AC power that is output to the AC power point on circuits HYA01 (OG/GN) (power) and HYA02 (OG/WH) (neutral). NOTE: The electrical device that is powered by the AC power point must not exceed 150 watts. NOTE: If the green LED is flashing, the AC power point may be overloaded, overheated or shorted. Unplug the electrical device from the AC power point and cycle the key. Refer to the Owner's Literature to determine if the electrical device is appropriate for the AC power point. This pinpoint test is intended to diagnose the following: - Fuses - Circuits - DC/AC inverter - AC power point PINPOINT TEST A: THE DC/AC INVERTER DOES NOT OPERATE CORRECTLY - NO POWER AT THE AC POWER POINT NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. ------------------------------------------------- A1 CHECK CIRCUITS SBP04 (GN/RD) AND CBP35 (YE/GY) FOR VOLTAGE - Ignition OFF. - Disconnect: DC/AC Inverter C2293a. - Ignition ON. - Measure the voltage between DC/AC inverter C2293a-1, circuit SBP04 (GN/RD), harness side and ground. - Measure the voltage between DC/AC inverter C2293a-3, circuit CBP35 (YE/GY), harness side and ground - Are the voltages greater than 10 volts? Yes GO to A2. No CHECK the Smart Junction Box (SJB) fuses 1 (30A) and 35 (10A). If OK, REPAIR the circuit(s). TEST the system for normal operation. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4424 A2 CHECK CIRCUIT GD182 (BK/GY) FOR AN OPEN - Ignition OFF. - Measure the resistance between DC/AC inverter C2293a-6, circuit GD182 (BK/GY), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to A3. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- A3 CHECK CIRCUITS HYA01 (OG/GN) AND HYA02 (OG/WH) FOR AN OPEN - Disconnect: AC Power Point C2292. - Disconnect: DC/AC Inverter C2293b. - Measure the resistance between DC/AC inverter C2293b-1, circuit HYA01 (OG/GN), harness side and AC power point C2292-1 circuit HYA01 (OG/GN), harness side; - Measure the resistance between DC/AC inverter C2293b-5, circuit HYA02 (OG/WH), harness side and AC power point C2292-3 circuit HYA02 (OG/WH), harness side. - Are the resistances less than 5 ohms? Yes GO to A4. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- A4 CHECK THE AC POWER POINT FOR AN OPEN - Measure the resistance between AC power point C2292-1, component side and AC power point C2292-2. - Measure the resistance between AC power point C2292-3, component side and AC power point C2292-1. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4425 - Are the resistances less than 5 ohms? Yes INSTALL a new DC/AC inverter. REFER to Direct Current/Alternating Current (DC/AC) Inverter See: Service and Repair/High Voltage Converter/Inverter/Direct Current/Alternating Current (DC/AC) Inverter. TEST the system for normal operation. No INSTALL a new AC power point. REFER to Alternating Current (AC) Powerpoint See: Service and Repair/High Voltage Converter/Inverter/Alternating Current (AC) Powerpoint. TEST the system for normal operation. ------------------------------------------------Pinpoint Test B: The DC/AC Inverter Does Not Operate Correctly - The AC Power Point LED Indicator Is Never On High-Voltage Converter/Inverter Pinpoint Tests Pinpoint Test B: The DC/AC Inverter Does Not Operate Correctly - The AC Power Point LED Indicator is Never On Refer to Wiring Diagram Set 12 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Charging System for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The DC/AC inverter receives 12 volts DC on circuits SBP04 (GN/RD) and CBP35 (YE/GY) and is grounded on circuit GD182 (BK/GY). The incoming DC power is internally converted to 60 cycle 110 volts AC power that is output to the AC power point on circuits HYA01 (OG/GN) (power) and HYA02 (OG/WH) (neutral). If a fault in the system is detected, the LED flashes when the key is in the ON position. The LED continuously illuminates if the system is operating correctly when the key is in the ON position. This pinpoint test is intended to diagnose the following: - Fuses - Circuits - DC/AC inverter - AC power point PINPOINT TEST B: THE DC/AC INVERTER DOES NOT OPERATE CORRECTLY - THE AC POWER POINT LED INDICATOR IS NEVER ON NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. ------------------------------------------------- B1 CHECK CIRCUIT CBP35 (YE/GY) FOR VOLTAGE - Ignition OFF. - Disconnect: DC/AC Inverter C2293a. - Ignition ON. - Measure the voltage between DC/AC inverter C2293a-3, circuit CBP35 (YE/GY), harness side and ground - Is the voltage greater than 10 volts? Yes Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4426 GO to B2. No CHECK the Smart Junction Box (SJB) fuse 35 (10A). If OK, REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- B2 CHECK CIRCUIT GD182 (BK/GY) FOR AN OPEN - Ignition OFF. - Measure the resistance between DC/AC inverter C2293a-6, circuit GD182 (BK/GY), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to B3. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- B3 CHECK CIRCUITS LYA03 (YE/VT) AND RYA03 (BU/BN) FOR AN OPEN - Disconnect: DC/AC Inverter C2293b. - Disconnect: AC Power Point C2292. - Measure the resistance between DC/AC inverter C2293b-9, circuit LYA03 (YE/VT), harness side and AC power point C2292-6 circuit LYA03 (YE/VT), harness side; and between DC/AC inverter C2293b-8, circuit RYA03 (BU/BN), harness side and AC power point C2292-5 circuit RYA03 (BU/BN), harness side. - Are the resistances less than 5 ohms? Yes GO to B4. No REPAIR the circuit(s). TEST the system for normal operation. ------------------------------------------------- B4 CHECK THE AC POWER POINT LED - Test the diode between AC power point C2292-5, component side and AC power point C2292-6, component side in both directions. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4427 - Is the resistance greater than 10,000 ohms in one direction and between 10-20 ohms in the opposite direction? Yes INSTALL a new DC/AC inverter. REFER to Direct Current/Alternating Current (DC/AC) Inverter See: Service and Repair/High Voltage Converter/Inverter/Direct Current/Alternating Current (DC/AC) Inverter. TEST the system for normal operation. No INSTALL a new AC power point. REFER to Alternating Current (AC) Powerpoint See: Service and Repair/High Voltage Converter/Inverter/Alternating Current (AC) Powerpoint. TEST the system for normal operation. ------------------------------------------------Pinpoint Test C: The DC/DC Converter Does Not Operate Correctly High-Voltage Converter/Inverter Pinpoint Tests Pinpoint Test C: The DC/DC Converter Does Not Operate Correctly Refer to Wiring Diagram Set 12 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Charging System for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The DC/DC converter is a liquid-cooled component that converts high voltage (216-397 volts) DC power to low voltage (12 volts) DC power while maintaining electrical isolation between the 2 DC power systems. The converter steps down the high voltage to 12 volts, providing power to the vehicle low voltage battery system. The PCM controls the operation of the DC/DC converter through an enable input from the PCM to the DC/DC converter. This pinpoint test is intended to diagnose the following: - PCM - 12-volt battery - Battery cables - DC/DC converter PINPOINT TEST C: THE DC/DC CONVERTER DOES NOT OPERATE CORRECTLY ------------------------------------------------- C1 CHECK THE PCM FOR DTCs WARNING: When servicing the high-voltage system, establish a buffer zone per the specified procedure. Failure to follow this instruction may result in serious personal injury or death. WARNING: Depower the high-voltage traction battery (HVTB) before carrying out any removal or installation procedures affecting the high-voltage battery system. Failure to follow this instruction may result in serious personal injury or death. WARNING: Wear high-voltage insulated safety gloves and a face shield when working with high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate safety and protection rating. Inspect the gloves before use and always wear them with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to follow these instructions may result in serious personal injury or death. WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious personal injury or death. - Enter the following diagnostic mode on the scan tool: Self Test/Retrieve and Record On-Demand and Continuous Memory DTCs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4428 - Are any PCM DTCs present? Yes For DTC P1A0C only, GO to C2. For all other DTCs, REFER to Computers and Control Systems Information. No GO to C2. ------------------------------------------------- C2 CHECK THE INTEGRITY OF THE 12-VOLT BATTERY - Ignition OFF. - Carry out the Battery - Condition Test to determine if the battery can hold a charge and is OK for use. Refer to Battery. See: Starting and Charging/Battery/Testing and Inspection/Pinpoint Tests - Did the battery pass the condition test? Yes GO to C3. No INSTALL a new 12-volt battery. ------------------------------------------------- C3 CHECK FOR CURRENT DRAINS - Carry out the Battery - Drain Test. Refer to the Diagnosis and Testing in Battery. See: Starting and Charging/Battery/Testing and Inspection/Component Tests and General Diagnostics See: Starting and Charging/Battery/Testing and Inspection - Are any circuits causing excessive current drains? Yes REPAIR as necessary. TEST the system for normal operation. No GO to C4. ------------------------------------------------- C4 CHECK THE VOLTAGE TO THE 12-VOLT BATTERY - Start the engine. - NOTE: The vehicle will start when the ignition switch is turned to the START position, but after a short period of time (approximately 2 minutes) the engine may shut down with the ignition switch still in the ON position. The DC/DC converter will output a normal charging rate with the engine running or not, but the engine MUST have run at least once. The state of charge of the High Voltage Traction Battery (HVTB) will have a direct affect on the length of engine running time. - With the engine running (ignition switch ON, engine must have run at least once), monitor the voltage at the 12-volt battery. - Is the voltage between 13.2-16.0 volts? Yes The system is operating correctly at this time. TEST the system for normal operation. No GO to C5. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4429 ------------------------------------------------- C5 CHECK THE POSITIVE 12-VOLT CABLE - With the engine running (ignition switch ON, engine must have run at least once), headlights on high beam and the heater blower fan on high, measure the voltage drop between DC/DC converter positive C1457c, post side and 12-volt battery positive C1100a, post side. - Is the voltage drop less than 0.75 volt? Yes GO to C6. No REPAIR or INSTALL a new 12-volt battery cable assembly as necessary. TEST the system for normal operation. ------------------------------------------------- C6 CHECK THE NEGATIVE 12-VOLT CABLE - With the engine running (ignition switch ON, engine must have run at least once), headlights on high beam and the heater blower fan on high, measure the voltage drop between DC/DC converter negative C1457b, post side and DC/DC converter ground G105, ground bolt side. - Is the voltage drop less than 0.25 volt? Yes GO to C7. No REPAIR or INSTALL a new 12-volt battery cable assembly as necessary. TEST the system for normal operation. ------------------------------------------------- C7 CHECK FOR CORRECT DC/DC CONVERTER OPERATION - Disconnect all of the DC/DC converter connectors. - Check for: corrosion. - pushed-out pins. - Connect all of the DC/DC converter connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new DC/DC converter. REFER to Direct Current/Direct Current (DC/DC) Converter See: Hybrid Drive Systems/Power Control System/Voltage Converter/Service and Repair/Direct Current/Direct Current (DC/DC) Converter. TEST the system for normal operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4430 No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. TEST the system for normal operation. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > High Voltage Converter/Inverter Auxiliary Power Outlet: Service and Repair High Voltage Converter/Inverter Alternating Current (AC) Powerpoint Alternating Current (AC) Powerpoint Removal and Installation 1. Disconnect the 12-volt battery. 2. Remove the console trim insert. 3. Disconnect the electrical connector and remove the AC power point. 4. To install, reverse the removal procedure. Direct Current/Alternating Current (DC/AC) Inverter Direct Current/Alternating Current (DC/AC) Inverter Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > High Voltage Converter/Inverter > Page 4433 Removal and Installation 1. Disconnect the 12-volt battery. 2. Remove the lower LH center instrument panel finish panel. 3. Disconnect the electrical connectors from the DC/AC inverter. 4. Remove the 2 DC/AC inverter nuts. - To install, tighten to 9 Nm (80 lb-in). 5. Remove the DC/AC inverter bolt. - To install, tighten 11 Nm (97 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > High Voltage Converter/Inverter > Page 4434 6. Remove the DC/AC inverter. 7. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > High Voltage Converter/Inverter > Page 4435 Auxiliary Power Outlet: Service and Repair Power Point Power Point Removal NOTE: Power point cover may differ depending on location. 1. Open the power point cover. 2. Install the Power Point Socket Remover in one of the power point socket slots. 3. Position the Power Point Socket Remover so that it engages in the adjacent slot. 4. Using the Power Point Socket Remover, pull the power point socket out of the retainer. 5. Disconnect the electrical connector. Installation 1. Connect the electrical connector. 2. Slide the power point socket into the retainer. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel Fuse: Locations Passenger Compartment Fuse Panel Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4443 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4444 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4445 Fuse: Locations Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4446 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4447 Fuse: Locations Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4448 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4449 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4450 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4451 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4452 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4453 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4454 Fuse: Locations Power Distribution Box Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel > Page 4455 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel Fuse: Application and ID Passenger Compartment Fuse Panel Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4458 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4459 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4460 Fuse: Application and ID Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4461 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4462 Fuse: Application and ID Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4463 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4464 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4465 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4466 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4467 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4468 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4469 Fuse: Application and ID Power Distribution Box Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 4470 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 4475 Fuse Block: Locations Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 4476 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 4477 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4480 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4481 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4482 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4483 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4484 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4485 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4486 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4487 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4488 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4489 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4490 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4491 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4492 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4493 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4494 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4495 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4496 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4497 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4498 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4499 Fuse Block: Connector Views Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4500 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4501 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4502 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4503 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4504 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4505 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 4509 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4514 Multiple Junction Connector: Diagrams C210 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4515 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4516 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4517 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4518 Multiple Junction Connector: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4519 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4520 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4521 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4522 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4523 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4524 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4525 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4526 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4527 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4528 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4529 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4530 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4531 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4532 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4533 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4534 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4535 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4536 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4537 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4538 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4539 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4540 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4541 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4542 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4543 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4544 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133 > Page 4545 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair Power Distribution Module: Service and Repair Smart Junction Box (SJB) Removal NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new Smart Junction Box (SJB) after installation. In the event that As-Built data is required (SJB will not communicate), all Remote Keyless Entry (RKE) devices must be programmed to the new SJB. A minimum of 2 RKE devices are necessary to complete the configuration and turn off the flashing interior lights. The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. NOTE: The steps included in the SJB removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered in a manufacturing mode with 7 pre-set DTCs related to the TPMS. To clear the DTCs, successful configuration of the SJB must occur, followed by successful TPMS sensor training, and a successful self-test. The DTCs are as follows: - B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) - B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is necessary only if the SJB is being replaced. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 4549 Upload the module configuration information from the SJB. 2. Remove the transmission selector lever bezel from the floor console finish panel. 3. Remove the floor console SJB cover. 4. Remove the floor console finish panel. 5. Disconnect the 7 electrical connectors. 6. Remove the 2 bolts and the SJB. Installation 1. Install the SJB. - Install the 2 bolts. - Connect the 7 electrical connectors. 2. Install the transmission selector lever bezel into the floor console finish panel. 3. NOTE: If the SJB was not replaced, this is the last step that is necessary. Install the floor console SJB cover. 4. NOTE: When successful, this step provides the calibration necessary for the SJB operation and clears DTCs B2477 and B106D. The clearing of these DTCs indicates the calibration data has been successfully downloaded to the new SJB. NOTE: The RKE transmitter portion of the Integrated Keyhead Transmitter (IKT) key is automatically transferred during Programmable Module Installation (PMI). Passive Anti-Theft System (PATS) programming is not necessary. If As-Built data is required during PMI, all remote transmitters (IKT or fob) must be programmed to the new SJB. Cycling the ignition to run for 6 seconds with each IKT will program the RKE function of the IKT key. NOTE: DTC B2276 may be set, indicating there are less than 2 transmitters programmed to the SJB. 5. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the SJB has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 6. NOTE: DTC C2780 will not clear if any other DTCs are present in the SJB. When successful, this step will clear DTC C2780. Carry out the SJB self-test (must include an on-demand self-test) and then repeat the self-test to confirm all DTCs have been cleared. 7. Rotate the instrument panel dimmer switch from the full dim position to the dome ON position. This will make sure that all displays are visible under all lighting conditions. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 4557 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair Power Distribution Module: Service and Repair Smart Junction Box (SJB) Removal NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new Smart Junction Box (SJB) after installation. In the event that As-Built data is required (SJB will not communicate), all Remote Keyless Entry (RKE) devices must be programmed to the new SJB. A minimum of 2 RKE devices are necessary to complete the configuration and turn off the flashing interior lights. The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. NOTE: The steps included in the SJB removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered in a manufacturing mode with 7 pre-set DTCs related to the TPMS. To clear the DTCs, successful configuration of the SJB must occur, followed by successful TPMS sensor training, and a successful self-test. The DTCs are as follows: - B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) - B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is necessary only if the SJB is being replaced. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 4561 Upload the module configuration information from the SJB. 2. Remove the transmission selector lever bezel from the floor console finish panel. 3. Remove the floor console SJB cover. 4. Remove the floor console finish panel. 5. Disconnect the 7 electrical connectors. 6. Remove the 2 bolts and the SJB. Installation 1. Install the SJB. - Install the 2 bolts. - Connect the 7 electrical connectors. 2. Install the transmission selector lever bezel into the floor console finish panel. 3. NOTE: If the SJB was not replaced, this is the last step that is necessary. Install the floor console SJB cover. 4. NOTE: When successful, this step provides the calibration necessary for the SJB operation and clears DTCs B2477 and B106D. The clearing of these DTCs indicates the calibration data has been successfully downloaded to the new SJB. NOTE: The RKE transmitter portion of the Integrated Keyhead Transmitter (IKT) key is automatically transferred during Programmable Module Installation (PMI). Passive Anti-Theft System (PATS) programming is not necessary. If As-Built data is required during PMI, all remote transmitters (IKT or fob) must be programmed to the new SJB. Cycling the ignition to run for 6 seconds with each IKT will program the RKE function of the IKT key. NOTE: DTC B2276 may be set, indicating there are less than 2 transmitters programmed to the SJB. 5. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the SJB has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 6. NOTE: DTC C2780 will not clear if any other DTCs are present in the SJB. When successful, this step will clear DTC C2780. Carry out the SJB self-test (must include an on-demand self-test) and then repeat the self-test to confirm all DTCs have been cleared. 7. Rotate the instrument panel dimmer switch from the full dim position to the dome ON position. This will make sure that all displays are visible under all lighting conditions. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4569 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4570 Relay Box: Locations Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4571 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4572 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4575 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4576 Relay Box: Diagrams Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4577 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4578 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4579 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4580 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4581 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) Relay Box: Application and ID Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 4584 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 4585 Relay Box: Application and ID Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 4586 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4591 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4592 Relay Box: Locations Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4593 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 4594 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4597 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4598 Relay Box: Diagrams Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4599 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4600 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4601 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4602 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4603 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) Relay Box: Application and ID Battery Junction Box (BJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 4606 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 4607 Relay Box: Application and ID Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 4608 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Ball Joint Deflection, Ride Height, Side-to-Side Lean, Tire Balance Weight, and Tire Inflation Alignment: Specifications Ball Joint Deflection, Ride Height, Side-to-Side Lean, Tire Balance Weight, and Tire Inflation Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Ball Joint Deflection, Ride Height, Side-to-Side Lean, Tire Balance Weight, and Tire Inflation > Page 4614 Alignment: Specifications Material Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Ball Joint Deflection, Ride Height, Side-to-Side Lean, Tire Balance Weight, and Tire Inflation > Page 4615 Alignment: Specifications Alignment Specifications Alignment Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Ball Joint Deflection, Ride Height, Side-to-Side Lean, Tire Balance Weight, and Tire Inflation > Page 4616 Alignment: Specifications Torque Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Alignment: Description and Operation Camber Wheel Alignment Angles Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 4619 Alignment: Description and Operation Caster Wheel Alignment Angles Caster Caster is the deviation from vertical of an imaginary line drawn through the pivot points (top of strut and lower ball joint), when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. The caster setting is not adjustable. A backward tilt is positive (+) and a forward tilt is negative (-). Front caster adjustment is not a separate procedure on this vehicle. The vehicle will tend to drift/pull toward the side with the lowest caster. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 4620 Alignment: Description and Operation Incorrect Thrust Angle (Dogtracking) Wheel Alignment Angles Incorrect Thrust Angle (Dogtracking) Incorrect thrust angle (also known as dogtracking) is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 4621 Alignment: Description and Operation Drift/Pull Wheel Alignment Angles Drift/Pull Pull is a tugging sensation felt by the hands on the steering wheel that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with the hands off the steering wheel. - A vehicle-related drift/pull on a flat road causes a consistent deviation from the straight-ahead path and requires constant steering input in the opposite direction to counteract the effect. - Drift/pull may be induced by conditions external to the vehicle (for example, wind or road crown). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 4622 Alignment: Description and Operation Camber Wheel Alignment Angles Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Wheel Alignment Angles Caster Caster is the deviation from vertical of an imaginary line drawn through the pivot points (top of strut and lower ball joint), when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. The caster setting is not adjustable. A backward tilt is positive (+) and a forward tilt is negative (-). Front caster adjustment is not a separate procedure on this vehicle. The vehicle will tend to drift/pull toward the side with the lowest caster. Incorrect Thrust Angle (Dogtracking) Wheel Alignment Angles Incorrect Thrust Angle (Dogtracking) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 4623 Incorrect thrust angle (also known as dogtracking) is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Drift/Pull Wheel Alignment Angles Drift/Pull Pull is a tugging sensation felt by the hands on the steering wheel that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with the hands off the steering wheel. - A vehicle-related drift/pull on a flat road causes a consistent deviation from the straight-ahead path and requires constant steering input in the opposite direction to counteract the effect. - Drift/pull may be induced by conditions external to the vehicle (for example, wind or road crown). Nibble Wheel Alignment Angles Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and experienced by the driver as small rotational oscillations of the steering wheel. Poor Groove Feel Wheel Alignment Angles Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Effort may be said to be "flat on-center." - Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of the gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. - In the diagnosis of a driveability problem, it is important to understand the difference between wander and poor groove feel. Poor Returnability/Sticky Steering Wheel Alignment Angles Poor Returnability/Sticky Steering Poor returnability and sticky steering are used to describe the poor return of the steering wheel to center after a turn or steering correction. Shimmy Wheel Alignment Angles Shimmy Shimmy, as experienced by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Toe Wheel Alignment Angles Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 4624 Toe Positive Toe (Toe In) Negative Toe (Toe Out) The vehicle toe setting affects tire wear and directional stability. Wander Wheel Alignment Angles Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Front Camber and Caster Adjustment 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 4 front strut upper mounting bracket nuts. 3. Push the front strut mounting bracket downward and turn it to the desired position to set the camber and caster. Both camber and caster for the front suspension are adjustable. For additional information, refer to Steps 4 and 5. 4. NOTE: Notice the position of the strut rod in each position. NOTE: Arrows shown in illustrations are pointing towards the front of the vehicle. Use the following table for LH side camber and or caster adjustment. 5. NOTE: Notice the position of the strut rod in each position. NOTE: Arrows shown in illustrations are pointing towards the front of the vehicle. Use the following table for the RH side camber and or caster adjustment. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 4627 6. Install the 4 front strut upper mounting bracket nuts. - Tighten to 40 Nm (30 lb-ft). 7. Recalibrate the steering wheel position sensor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 4628 Alignment: Service and Repair Ride Height Measurement Ride Height Measurement Front Ride Height Measurement NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have a full tank of fuel. 1. Position a suitable surface gauge (such as Starrett 57D Surface Gauge), on a flat, level surface and adjust the gauge's arm until the scriber point is located in the center of the lower ball joint bolt. Lock the surface gauge in this position. 2. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement 2). 3. Position the surface gauge on the same flat, level surface as used in Step 1, adjust the gauge's arm until the scriber point is located in the center of the forward lower arm bolt. Lock the surface gauge in this position. 4. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement 3). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 4629 5. Subtract measurement 3 from measurement 2 to obtain the front ride height. - Refer to Specifications. Rear Ride Height Measurement NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have a full tank of fuel. 1. Measure the distance between the flat level surface and the center of the shock absorber lower bolt (measurement 2). 2. Measure the distance between the flat level surface and the center of the lower arm inner bolt (measurement 3). 3. Subtract measurement 2 from measurement 3 to obtain the rear ride height. - Refer to Specifications. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 4630 Alignment: Service and Repair Toe Adjustment Toe Adjustment Front Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off. Hold the steering wheel in the straight-ahead position using a suitable holding device. 3. Check the toe settings following 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 steering gear bellows clamp(s). 5. Loosen the tie-rod end jam nut(s). - Clean and lubricate the nut(s) and front wheel spindle tie-rod threads. 6. Rotate the front wheel spindle tie rods to increase or decrease the front toe. 7. NOTICE: Hold the tie-rod end stationary with a wrench while tightening the nut, or damage to the boot can occur. NOTE: Do not disturb the toe settings while tightening the nut(s). Tighten the tie-rod end jam nut(s) to 40 Nm (30 lb-ft). 8. Install the steering gear bellows clamp(s). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 4631 9. Check the toe settings. Follow the equipment manufacturer's instructions. 10. Calibrate the steering wheel position sensor. Rear Toe Adjustment 1. NOTICE: The cam nut and cam bolt area must be free of foreign material to make sure of correct clamping. NOTE: Clean the general area of the joint to prevent foreign material from entering the joint. Clean the area using only mild liquids. NOTE: Jounce the vehicle to make sure that the suspension is in its normal, at-rest position. Check the toe setting using suitable wheel alignment equipment. 2. NOTE: Do not remove the rear knuckle cam nut and wheel knuckle bolts. If removed, clean the serrations in the bushing sleeve with a wire brush and install a new wheel knuckle bolt and cam nut. Loosen the LH and RH rear wheel knuckle bolts. 3. Turn the LH and RH adjusting cams simultaneously until the toe is within specification. 4. Tighten the LH and RH rear wheel knuckle bolts. - Using a suitable tool, hold the adjustment cam nut stationary while tightening the rear wheel knuckle bolt. - Tighten to 150 Nm (111 lb-ft). 5. Calibrate the steering wheel position sensor. For additional information, refer to Steering Wheel Position Sensor Calibration in the Diagnosis and Testing of Steering. See: Steering/Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 4637 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 4638 Steering Control Module: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 4639 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Programming and Relearning. NOTE: The Tire Pressure Monitoring System (TPMS) Training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. NOTE: Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place at the valve stem. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall at the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall at the valve stem and press and release the test button to train the RF tire pressure sensor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 4646 8. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 4647 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" when a vehicle is stationary to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall at the tire valve stem. 3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. This feedback may not always be present, do not rely on it to reflect the most recent pressure data. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. If the sensor still does not respond, attempt to activate the same sensor again using the customer activation tool (if available). If the sensor still fails to train, attempt to train the sensor with the vehicle doors open. Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor. Activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel Front Steering Knuckle: Customer Interest ABS/TCS - Clicking Noise From Left Front Wheel TSB 09-5-5 03/23/09 LEFT FRONT ABS SENSOR CONTACTING TONE RING - VEHICLES BUILT 10/21/2008-10/31/2008 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built from 10/21/2008 to 10/31/2008 may exhibit a clicking or rubbing noise from the left front wheel speed sensor and/or exhibit ABS warning light activation. The left front wheel knuckle may have been machined incorrectly allowing the wheel speed sensor to contact the tone ring. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Measure the air gap between the left front wheel speed sensor and tone ring with a feeler gage. 2. If 0.02" (0.50 mm) or more - this procedure does not apply. Continue with normal diagnostics. 3. If less than 0.02" (0.5 mm) or evidence of contact - replace the left front wheel knuckle per Workshop Manual (WSM), Section 204-01 and the left front Wheel Speed Sensor per WSM, Section 206-09. Parts Block 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 090505A 2009 Escape Hybrid, 1.3 Hrs. Mariner Hybrid: Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Be Claimed With Operations B And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505A 2009 Escape, Mariner: 1.2 Hrs. Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel > Page 4657 Be Claimed With Operations B And/Or C (Do Not Use With 2001 B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505B 2009 Escape, Mariner, 0.6 Hr. Escape Hybrid, Mariner Hybrid: Check Caster, Camber And Toe In Can Be Claimed With Operation A And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505C 2009 Escape, Mariner, 0.2 Hr. Escape Hybrid, Mariner Hybrid: Correct Toe-In Can Be Claimed With Operation A And B (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 3K186 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 09-5-5 > Mar > 09 > ABS/TCS Clicking Noise From Left Front Wheel Front Steering Knuckle: All Technical Service Bulletins ABS/TCS - Clicking Noise From Left Front Wheel TSB 09-5-5 03/23/09 LEFT FRONT ABS SENSOR CONTACTING TONE RING - VEHICLES BUILT 10/21/2008-10/31/2008 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built from 10/21/2008 to 10/31/2008 may exhibit a clicking or rubbing noise from the left front wheel speed sensor and/or exhibit ABS warning light activation. The left front wheel knuckle may have been machined incorrectly allowing the wheel speed sensor to contact the tone ring. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Measure the air gap between the left front wheel speed sensor and tone ring with a feeler gage. 2. If 0.02" (0.50 mm) or more - this procedure does not apply. Continue with normal diagnostics. 3. If less than 0.02" (0.5 mm) or evidence of contact - replace the left front wheel knuckle per Workshop Manual (WSM), Section 204-01 and the left front Wheel Speed Sensor per WSM, Section 206-09. Parts Block 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 090505A 2009 Escape Hybrid, 1.3 Hrs. Mariner Hybrid: Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Be Claimed With Operations B And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505A 2009 Escape, Mariner: 1.2 Hrs. Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 09-5-5 > Mar > 09 > ABS/TCS Clicking Noise From Left Front Wheel > Page 4663 Be Claimed With Operations B And/Or C (Do Not Use With 2001 B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505B 2009 Escape, Mariner, 0.6 Hr. Escape Hybrid, Mariner Hybrid: Check Caster, Camber And Toe In Can Be Claimed With Operation A And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505C 2009 Escape, Mariner, 0.2 Hr. Escape Hybrid, Mariner Hybrid: Correct Toe-In Can Be Claimed With Operation A And B (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 3K186 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 4664 Front Steering Knuckle: Service and Repair Wheel Knuckle Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. 1. Remove the brake disc. 2. Remove and discard the wheel hub nut. 3. Using the Front Hub Remover, separate the outer CV joint spindle from the wheel hub. 4. Remove and discard the tie-rod end nut. 5. NOTICE: Do not use a hammer to separate the tie-rod end from the wheel knuckle or damage to the wheel knuckle can result. NOTICE: Do not damage the tie-rod end boot while installing the Tie-Rod End Remover. Using the Tie-Rod End Remover, separate the tie rod from the wheel knuckle. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 4665 6. Remove and discard the lower ball joint bolt and nut. 7. Remove the wheel speed sensor bolt and position the sensor aside. 8. Separate the lower ball joint from the wheel knuckle. 9. Remove the 2 strut-to-knuckle nuts, bolts and the wheel knuckle. - Discard the nuts and bolts. Installation 1. Position the wheel knuckle and install the 2 new strut-to-knuckle bolts and nuts. - Tighten to 115 Nm (85 lb-ft). 2. Position and align the ball joint stud into the wheel knuckle. 3. Install the new lower ball joint bolt and nut. - To install, tighten to 63 Nm (46 lb-ft). 4. Install the wheel speed sensor and the bolt. - Tighten to 9 Nm (80 lb-in). 5. Position the tie-rod end into the wheel knuckle and install the new tie-rod end nut. - Tighten to 80 Nm (59 lb-ft). 6. Using the Halfshaft Installer, install the halfshaft into the wheel hub. 7. Install the brake disc. 8. NOTICE: Do not tighten the front wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied. NOTE: Apply the brake to keep the halfshaft from rotating. Install the new front wheel hub nut. - Tighten to 300 Nm (221 lb-ft). 9. Check and, if necessary, align the front end. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Power Steering This vehicle is equipped with a Electric Power Assisted Steering (EPAS) System. There is no fluid reservoir to check or fill. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 4673 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 4674 Steering Control Module: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 4675 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 4680 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 4681 Steering Control Module: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 4682 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering Supplemental Restraint System (SRS) Depowering and Repowering Depowering Procedure WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 OFF. 3. At the Smart Junction Box (SJB), located at the RH side of the center console, remove the cover and the RCM fuse 32 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition from OFF to ON. 2. Install RCM fuse 32 (10A) to the SJB and install the cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 4688 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 4. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the 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 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 4689 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 to OFF. 3. At the Smart Junction Box (SJB) located at the RH side of the center console, remove the cover and the RCM fuse 32 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Using a 3-mm Allen wrench or a suitable tool, place it in the driver air bag module release hole on the underside of the steering wheel. 8. NOTICE: During driver air bag module removal, make sure all 3 driver air bag module hooks are released from the steering wheel wire Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 4690 clip. Failure to do so may cause damage to the driver air bag module and or the steering wheel. NOTE: The driver air bag module is removed for clarity. Position the 3-mm Allen wrench or suitable tool against the wire clip and push inward disengaging the wire clip from the 3 driver air bag module hooks. 9. Disconnect the horn electrical connector. Then disconnect the 2 driver air bag module electrical connectors and remove the driver air bag module. 10. Open and lower the glove compartment door. 11. Remove the 2 passenger air bag module bolts. 12. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Failure to follow this instruction may result in vehicle damage, equipment damage, component damage and/or system failure. NOTE: Use care when removing the passenger air bag module from the instrument panel. The passenger air bag module can drop down during removal and the passenger air bag module rear bracket can scratch the front of the instrument panel. Through the glove compartment opening, release the passenger air bag module deployment door clips while pushing the passenger air bag module out of the instrument panel. 13. Remove the passenger air bag module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 4691 1. Disconnect the 2 passenger air bag module electrical connectors. 2. Detach the wire harness routing clip and remove the passenger air bag module. 14. From under the rear of the passenger seat, slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 15. Remove the passenger side D-pillar trim panel. 1. Separate the weatherstrip. 2. Pull out and separate the quarter trim panel at the D-pillar trim panel. 3. Pull out to release the retainers and remove the D-pillar trim panel. 16. Disconnect the passenger side safety canopy module electrical connector. 17. Remove the driver side D-pillar trim panel. 1. Separate the weatherstrip. 2. Pull out and separate the quarter trim panel at the D-pillar trim panel. 3. Pull out to release the retainers and remove the D-pillar trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 4692 18. Disconnect the driver side safety canopy module electrical connector. 19. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 20. Install RCM fuse 32 (10A) to the SJB. 21. Connect the battery ground cable. Reactivation 1. Remove RCM fuse 32 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 4. Connect the driver side safety canopy module electrical connector. 5. Install the driver side D-pillar trim panel. 1. Engage the D-pillar trim panel to the quarter trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 4693 2. Install the D-pillar trim panel. 3. Install the weatherstrip. 6. Connect the passenger side safety canopy module electrical connector. 7. Install the passenger side D-pillar trim panel. 1. Engage the D-pillar trim panel to the quarter trim panel. 2. Install the D-pillar trim panel. 3. Install the weatherstrip. 8. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 9. NOTICE: During passenger air bag module installation, make sure the passenger air bag module wire harness routing clip is attached to the passenger air bag module. Failure to follow this instruction may result in wiring harness damage. NOTICE: The passenger air bag module electrical connectors are unique and cannot be reversed when connected to the passenger air bag module. Match the electrical connector key to the keyway in the passenger air bag module. Do not force the electrical connectors into the passenger air bag module. Failure to follow these instructions may result in component and/or connector damage. Install the passenger air bag module. 1. Connect the 2 passenger air bag module electrical connectors. 2. Attach the wire harness routing clip. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 4694 10. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Failure to follow this instruction may result in vehicle damage, equipment damage, component damage and/or system failure. NOTE: During passenger air bag module installation, make sure all the deployment door clips are fully seated into the instrument panel. NOTE: Use care when installing the passenger air bag module in the instrument panel. The passenger air bag module rear bracket can scratch the front of the instrument panel. Position the passenger air bag module and seat the passenger air bag module deployment door clips into the instrument panel. 11. Install the 2 passenger air bag module bolts. - To install, tighten to 8 Nm (71 lb-in). 12. Close the glove compartment door. 13. Install the driver air bag module electrical connectors fully into the driver air bag module. Then connect the horn electrical connector. 14. NOTE: Make sure the driver air bag module wiring harness is routed down and away from the driver air bag module hooks during installation. NOTE: Audible clicks will be heard when the 3 wire clips are seated in the 3 driver air bag module hooks. Align the driver air bag module hooks to the steering wheel and, while pushing inward, seat the 3 driver air bag module hooks to the steering wheel wire clip. - When the 3 driver air bag module hooks are seated in place, gently pull outward at the corners of the driver air bag module to make sure that the 3 hooks are fully seated. There should also be an even gap between the driver air bag module trim cover and the steering wheel. Check the driver air bag module and trim cover for correct movement when applying the horn. 15. Turn the ignition switch from OFF to ON. 16. Install RCM fuse 32 (10A) to the SJB and install the cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 4695 17. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 18. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Customer Interest for Steering Damper: > 10-18-8 > Sep > 10 > Steering - Steering Wheel Nibble In Cold Temps Steering Damper: Customer Interest Steering - Steering Wheel Nibble In Cold Temps TSB 10-18-8 09/27/10 VIBRATION/STEERING WHEEL NIBBLE - COLD TEMPERATURES FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner This article supersedes TSB 10-12-7 to update the Part List. ISSUE Some 2008-2010 Escape and Mariner vehicles may exhibit a vibration or nibble in the steering wheel while driving at 55-75 MPH (88-121 Km/h) in cold ambient temperatures of 5-25 °F (-15 to -4 °C). The vibration/nibble may be perceived as a tire or driveshaft balance issue. A steering wheel damper has been developed to correct this condition. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check and adjust tire air pressure as required. Refer to the Workshop Manual (WSM), Section 204-04. 2. Install the Rotunda Mastertech MTS-4000 Analyzer (257-00018) or equivalent. 3. Road test the vehicle for 15 minutes and record the vibration frequency. a. If the vibration goes away during the test drive, discontinue this procedure. The concern is due to temporary tire flat spotting which is a normal tire condition. Refer to WSM, Section 204-04. b. If the vibration remains and the vibration frequency is within the range of 27-33 Hz proceed to Step 4. c. If the vibration frequency not within the range of 27-33 Hz, do not continue with this procedure. Follow normal WSM diagnostic. Refer to WSM, Section 100-04. 4. Install a revised steering wheel damper. a. Remove steering wheel. Refer to the WSM, Section 211-04. b. Remove the trim cover from the rear of the steering wheel. c. Remove the three (3) damper bracket screws from the steering wheel and remove steering damper. (Figure 1) d. Attach revised steering wheel damper using existing screws. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Customer Interest for Steering Damper: > 10-18-8 > Sep > 10 > Steering - Steering Wheel Nibble In Cold Temps > Page 4704 e. Install steering wheel trim cover and steering wheel. Refer to the WSM, Section 211-04. Parts Block 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 101808A 2008-2010 Escape, 0.7 Hr. Mariner: Includes Time To Install Diagnostic Equipment And Road Test To Correct Flat Spots On Tires. (Do Not Use With Any Other Labor Operations) 101808B 2008-2010 Escape, 1.3 Hrs. Mariner: Includes Time To Install Diagnostic Equipment And Road Test To Correct Flat Spots On Tires, Condition Still Present Install The Revised Steering Wheel Damper (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 4R602 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > 10-18-8 > Sep > 10 > Steering - Steering Wheel Nibble In Cold Temps Steering Damper: All Technical Service Bulletins Steering - Steering Wheel Nibble In Cold Temps TSB 10-18-8 09/27/10 VIBRATION/STEERING WHEEL NIBBLE - COLD TEMPERATURES FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner This article supersedes TSB 10-12-7 to update the Part List. ISSUE Some 2008-2010 Escape and Mariner vehicles may exhibit a vibration or nibble in the steering wheel while driving at 55-75 MPH (88-121 Km/h) in cold ambient temperatures of 5-25 °F (-15 to -4 °C). The vibration/nibble may be perceived as a tire or driveshaft balance issue. A steering wheel damper has been developed to correct this condition. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check and adjust tire air pressure as required. Refer to the Workshop Manual (WSM), Section 204-04. 2. Install the Rotunda Mastertech MTS-4000 Analyzer (257-00018) or equivalent. 3. Road test the vehicle for 15 minutes and record the vibration frequency. a. If the vibration goes away during the test drive, discontinue this procedure. The concern is due to temporary tire flat spotting which is a normal tire condition. Refer to WSM, Section 204-04. b. If the vibration remains and the vibration frequency is within the range of 27-33 Hz proceed to Step 4. c. If the vibration frequency not within the range of 27-33 Hz, do not continue with this procedure. Follow normal WSM diagnostic. Refer to WSM, Section 100-04. 4. Install a revised steering wheel damper. a. Remove steering wheel. Refer to the WSM, Section 211-04. b. Remove the trim cover from the rear of the steering wheel. c. Remove the three (3) damper bracket screws from the steering wheel and remove steering damper. (Figure 1) d. Attach revised steering wheel damper using existing screws. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > 10-18-8 > Sep > 10 > Steering - Steering Wheel Nibble In Cold Temps > Page 4710 e. Install steering wheel trim cover and steering wheel. Refer to the WSM, Section 211-04. Parts Block 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 101808A 2008-2010 Escape, 0.7 Hr. Mariner: Includes Time To Install Diagnostic Equipment And Road Test To Correct Flat Spots On Tires. (Do Not Use With Any Other Labor Operations) 101808B 2008-2010 Escape, 1.3 Hrs. Mariner: Includes Time To Install Diagnostic Equipment And Road Test To Correct Flat Spots On Tires, Condition Still Present Install The Revised Steering Wheel Damper (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 4R602 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Steering Gear: Service and Repair Steering Gear Steering Gear Steering Gear - Exploded View Removal and Installation All vehicles 1. Remove the front wheels and tires. 2. Turn the ignition key to the OFF position. - Remove the ignition key. 3. NOTICE: Do not allow the steering wheel to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Air Bag Systems. Remove and discard the steering column coupling-to-steering gear bolt and disconnect the coupling from the steering gear. To install, tighten the new bolt to 55 Nm (41 lb-ft). 4. From the engine compartment, loosen the 2 steering gear bolts. 5. If equipped, remove the 3 pin-type retainers and the steering gear shield. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear > Page 4715 6. Remove and discard the 2 outer tie-rod end nuts. - To install, tighten the new nuts to 80 Nm (59 lb-ft). 7. NOTICE: Do not use a hammer to separate the tie-rod end from the wheel knuckle or damage to the wheel knuckle can result. Using the Ball Joint Separator, separate the tie-rod ends from the wheel knuckles. All-Wheel Drive (AWD) vehicles (except Hybrid) 8. Remove the rear transaxle insulator through bolt. - To install, tighten to 90 Nm (66 lb-ft). Front Wheel Drive (FWD) vehicles with automatic transaxle - 2.5L 9. Remove the 3 transmission damper bolts and the transmission damper. - To install, tighten to 40 Nm (30 lb-ft). All vehicles 10. Remove and discard the 2 steering gear bolts. - To install, tighten the new bolts to 125 Nm (92 lb-ft). 11. NOTE: For All-Wheel Drive (AWD) vehicles (except Hybrid), it is necessary to grasp the driveshaft by hand and apply slight downward pressure to obtain clearance for the removal of the steering gear. Rotate the steering gear 90 degrees clockwise and remove it from the LH side of the vehicle. 12. To install, reverse the removal procedure. 13. Check and, if necessary, align the front end. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear > Page 4716 Steering Gear: Service and Repair Steering Gear Boot Steering Gear Boot Removal and Installation 1. Remove the outer tie-rod end. For additional information, refer to Tie Rod End - Outer See: Tie Rod/Service and Repair/Tie Rod End - Outer. 2. Remove the tie-rod end jam nut. 3. Remove and discard the 2 steering gear boot clamps and the steering gear boot. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 10-13-2 > Jul > 10 > Steering - Steering Column Pop/Clunk On Turns Steering Shaft: All Technical Service Bulletins Steering - Steering Column Pop/Clunk On Turns TSB 10-13-2 07/19/10 STEERING COLUMN POP/CLUNK NOISE ON TURNS - BUILT ON OR BEFORE 6/11/2010 FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner This article supersedes TSB 09-22-18 to update the production fix date and Service Procedure. ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 6/11/2010 may exhibit a pop or clunk noise from the steering column area while turning. This noise typically occurs quarter turn before the steering wheel reaches it's end of travel stop and typically goes away with weight off the wheels. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FAILURE TO PERFORM STEERING WHEEL POSITION SENSOR CALIBRATION PROCEDURE, AFTER STEERING COLUMN REPLACEMENT, MAY RESULT IN STEERING COLUMN NOISE ON TURNS. 1. Verify noise is coming from steering column and/or steering shaft area and occurs before steering wheel reaches it's end of travel stop. a. If noise is only present when the steering wheel contacts end of travel stop, it is a normal characteristic of the vehicle and this procedure does not apply. b. If noise is present before or between steering wheel end of travel stop, proceed to Step 2. 2. Replace both the steering shaft and steering shaft coupling u-joint per online Workshop Manual (WSM), Section 211-04. a. Torque the steering column coupling-to-steering column shaft bolt to 52 lb-ft (70 N.m). 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 101302A 2008-2010 Escape, 0.9 Hr. Mariner: Replace The Steering Shaft And Coupling U-Joint Includes Time To Diagnose Concern (Do Not Use With Any Other Labor Operations) DEALER CODING Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 10-13-2 > Jul > 10 > Steering - Steering Column Pop/Clunk On Turns > Page 4725 CONDITION BASIC PART NO. CODE 3B676 14 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 10-13-2 > Jul > 10 > Steering - Steering Column Pop/Clunk On Turns Steering Shaft: Customer Interest Steering - Steering Column Pop/Clunk On Turns TSB 10-13-2 07/19/10 STEERING COLUMN POP/CLUNK NOISE ON TURNS - BUILT ON OR BEFORE 6/11/2010 FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner This article supersedes TSB 09-22-18 to update the production fix date and Service Procedure. ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 6/11/2010 may exhibit a pop or clunk noise from the steering column area while turning. This noise typically occurs quarter turn before the steering wheel reaches it's end of travel stop and typically goes away with weight off the wheels. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FAILURE TO PERFORM STEERING WHEEL POSITION SENSOR CALIBRATION PROCEDURE, AFTER STEERING COLUMN REPLACEMENT, MAY RESULT IN STEERING COLUMN NOISE ON TURNS. 1. Verify noise is coming from steering column and/or steering shaft area and occurs before steering wheel reaches it's end of travel stop. a. If noise is only present when the steering wheel contacts end of travel stop, it is a normal characteristic of the vehicle and this procedure does not apply. b. If noise is present before or between steering wheel end of travel stop, proceed to Step 2. 2. Replace both the steering shaft and steering shaft coupling u-joint per online Workshop Manual (WSM), Section 211-04. a. Torque the steering column coupling-to-steering column shaft bolt to 52 lb-ft (70 N.m). 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 101302A 2008-2010 Escape, 0.9 Hr. Mariner: Replace The Steering Shaft And Coupling U-Joint Includes Time To Diagnose Concern (Do Not Use With Any Other Labor Operations) DEALER CODING Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 10-13-2 > Jul > 10 > Steering - Steering Column Pop/Clunk On Turns > Page 4731 CONDITION BASIC PART NO. CODE 3B676 14 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Page 4732 Steering Shaft: Service and Repair Steering Column Shaft Removal and Installation 1. Remove the steering column opening trim. 2. Remove the LH instrument panel side finish panel. 3. Through the side finish panel opening, remove the ground wire eyelet bolt. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Page 4733 - Position the 2 ground wire eyelets and wires aside. 4. Through the side finish panel opening, disconnect the 2 instrument panel wiring harness electrical connectors and, if equipped, the battery high-voltage jumper switch electrical connector. Position the connectors and harnesses aside. 5. Turn the ignition switch to the ON position and rotate the steering wheel clockwise until the steering column coupling-to-steering column bolt is accessible. 6. Through the side finish panel opening, remove and discard the steering column shaft coupling-to-steering column bolt. - To install, tighten the new bolt to 55 Nm (41 lb-ft). 7. Turn the ignition switch to the LOCK position and remove the key. - Rotate the steering wheel counter clockwise until the column locks. 8. NOTICE: Do not allow the steering column shaft to rotate while the lower shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Air Bag Systems. Separate the steering column coupling from the steering column. 9. Remove the 3 steering column dash seal nuts. - To install, tighten to 8 Nm (71 lb-in). 10. From the passenger compartment, slide the dash seal upwards on the steering column shaft. 11. Remove and discard the steering column coupling-to-steering column shaft bolt. - To install, tighten the new bolt to 55 Nm (41 lb-ft). 12. Remove the steering column shaft and dash seal. 13. Remove the steering column dash seal from the shaft. - Inspect the dash seal and clip-type retainers for damage and, if necessary, install a new dash seal. 14. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Customer Interest: > 10-13-2 > Jul > 10 > Steering - Steering Column Pop/Clunk On Turns Steering Shaft Coupler: Customer Interest Steering - Steering Column Pop/Clunk On Turns TSB 10-13-2 07/19/10 STEERING COLUMN POP/CLUNK NOISE ON TURNS - BUILT ON OR BEFORE 6/11/2010 FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner This article supersedes TSB 09-22-18 to update the production fix date and Service Procedure. ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 6/11/2010 may exhibit a pop or clunk noise from the steering column area while turning. This noise typically occurs quarter turn before the steering wheel reaches it's end of travel stop and typically goes away with weight off the wheels. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FAILURE TO PERFORM STEERING WHEEL POSITION SENSOR CALIBRATION PROCEDURE, AFTER STEERING COLUMN REPLACEMENT, MAY RESULT IN STEERING COLUMN NOISE ON TURNS. 1. Verify noise is coming from steering column and/or steering shaft area and occurs before steering wheel reaches it's end of travel stop. a. If noise is only present when the steering wheel contacts end of travel stop, it is a normal characteristic of the vehicle and this procedure does not apply. b. If noise is present before or between steering wheel end of travel stop, proceed to Step 2. 2. Replace both the steering shaft and steering shaft coupling u-joint per online Workshop Manual (WSM), Section 211-04. a. Torque the steering column coupling-to-steering column shaft bolt to 52 lb-ft (70 N.m). 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 101302A 2008-2010 Escape, 0.9 Hr. Mariner: Replace The Steering Shaft And Coupling U-Joint Includes Time To Diagnose Concern (Do Not Use With Any Other Labor Operations) DEALER CODING Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Customer Interest: > 10-13-2 > Jul > 10 > Steering - Steering Column Pop/Clunk On Turns > Page 4742 CONDITION BASIC PART NO. CODE 3B676 14 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-13-2 > Jul > 10 > Steering - Steering Column Pop/Clunk On Turns Steering Shaft Coupler: All Technical Service Bulletins Steering - Steering Column Pop/Clunk On Turns TSB 10-13-2 07/19/10 STEERING COLUMN POP/CLUNK NOISE ON TURNS - BUILT ON OR BEFORE 6/11/2010 FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner This article supersedes TSB 09-22-18 to update the production fix date and Service Procedure. ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 6/11/2010 may exhibit a pop or clunk noise from the steering column area while turning. This noise typically occurs quarter turn before the steering wheel reaches it's end of travel stop and typically goes away with weight off the wheels. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FAILURE TO PERFORM STEERING WHEEL POSITION SENSOR CALIBRATION PROCEDURE, AFTER STEERING COLUMN REPLACEMENT, MAY RESULT IN STEERING COLUMN NOISE ON TURNS. 1. Verify noise is coming from steering column and/or steering shaft area and occurs before steering wheel reaches it's end of travel stop. a. If noise is only present when the steering wheel contacts end of travel stop, it is a normal characteristic of the vehicle and this procedure does not apply. b. If noise is present before or between steering wheel end of travel stop, proceed to Step 2. 2. Replace both the steering shaft and steering shaft coupling u-joint per online Workshop Manual (WSM), Section 211-04. a. Torque the steering column coupling-to-steering column shaft bolt to 52 lb-ft (70 N.m). 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 101302A 2008-2010 Escape, 0.9 Hr. Mariner: Replace The Steering Shaft And Coupling U-Joint Includes Time To Diagnose Concern (Do Not Use With Any Other Labor Operations) DEALER CODING Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-13-2 > Jul > 10 > Steering - Steering Column Pop/Clunk On Turns > Page 4748 CONDITION BASIC PART NO. CODE 3B676 14 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft Coupler: > 09-15-1 > Aug > 09 > ABS/TCS Traction Control Lamp ON/DTC C1440 Set Brake Light Switch: All Technical Service Bulletins ABS/TCS - Traction Control Lamp ON/DTC C1440 Set TSB 09-15-1 08/10/09 TRACTION CONTROL LIGHT WITH DTC C1440 - BUILT 6/1/2009-6/10/2009 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built on or between 6/1/2009 to 6/10/2009, may exhibit the traction control light on with DTC code C1440. If the vehicle is operated for an extended period following the illumination of the traction control light, a slight brake drag condition may be observed. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE If the vehicle was built on or between 6/01/2009 to 6/10/2009, and both the traction control light and DTC C1440 are present, then replace the brake pedal switch. If only one is present, and not the other, then proceed with normal diagnostics. Refer to Workshop Manual (WSM), Section 417-01 for brake pedal switch replacement. NOTE DO NOT PRESS OR PULL ON BRAKE PEDAL WHEN INSTALLING OR REMOVING THE STOPLAMP SWITCH OTHERWISE MISADJUSTMENT OR DAMAGE TO THE STOPLAMP SWITCH CAN OCCUR. Parts Block 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 091501A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Replace The Stoplamp Switch. Includes Time To Check For DTCs (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 13480 12 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 10-18-8 > Sep > 10 > Steering - Steering Wheel Nibble In Cold Temps Steering Wheel: Customer Interest Steering - Steering Wheel Nibble In Cold Temps TSB 10-18-8 09/27/10 VIBRATION/STEERING WHEEL NIBBLE - COLD TEMPERATURES FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner This article supersedes TSB 10-12-7 to update the Part List. ISSUE Some 2008-2010 Escape and Mariner vehicles may exhibit a vibration or nibble in the steering wheel while driving at 55-75 MPH (88-121 Km/h) in cold ambient temperatures of 5-25 °F (-15 to -4 °C). The vibration/nibble may be perceived as a tire or driveshaft balance issue. A steering wheel damper has been developed to correct this condition. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check and adjust tire air pressure as required. Refer to the Workshop Manual (WSM), Section 204-04. 2. Install the Rotunda Mastertech MTS-4000 Analyzer (257-00018) or equivalent. 3. Road test the vehicle for 15 minutes and record the vibration frequency. a. If the vibration goes away during the test drive, discontinue this procedure. The concern is due to temporary tire flat spotting which is a normal tire condition. Refer to WSM, Section 204-04. b. If the vibration remains and the vibration frequency is within the range of 27-33 Hz proceed to Step 4. c. If the vibration frequency not within the range of 27-33 Hz, do not continue with this procedure. Follow normal WSM diagnostic. Refer to WSM, Section 100-04. 4. Install a revised steering wheel damper. a. Remove steering wheel. Refer to the WSM, Section 211-04. b. Remove the trim cover from the rear of the steering wheel. c. Remove the three (3) damper bracket screws from the steering wheel and remove steering damper. (Figure 1) d. Attach revised steering wheel damper using existing screws. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 10-18-8 > Sep > 10 > Steering - Steering Wheel Nibble In Cold Temps > Page 4767 e. Install steering wheel trim cover and steering wheel. Refer to the WSM, Section 211-04. Parts Block 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 101808A 2008-2010 Escape, 0.7 Hr. Mariner: Includes Time To Install Diagnostic Equipment And Road Test To Correct Flat Spots On Tires. (Do Not Use With Any Other Labor Operations) 101808B 2008-2010 Escape, 1.3 Hrs. Mariner: Includes Time To Install Diagnostic Equipment And Road Test To Correct Flat Spots On Tires, Condition Still Present Install The Revised Steering Wheel Damper (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 4R602 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 10-18-8 > Sep > 10 > Steering - Steering Wheel Nibble In Cold Temps Steering Wheel: All Technical Service Bulletins Steering - Steering Wheel Nibble In Cold Temps TSB 10-18-8 09/27/10 VIBRATION/STEERING WHEEL NIBBLE - COLD TEMPERATURES FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner This article supersedes TSB 10-12-7 to update the Part List. ISSUE Some 2008-2010 Escape and Mariner vehicles may exhibit a vibration or nibble in the steering wheel while driving at 55-75 MPH (88-121 Km/h) in cold ambient temperatures of 5-25 °F (-15 to -4 °C). The vibration/nibble may be perceived as a tire or driveshaft balance issue. A steering wheel damper has been developed to correct this condition. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check and adjust tire air pressure as required. Refer to the Workshop Manual (WSM), Section 204-04. 2. Install the Rotunda Mastertech MTS-4000 Analyzer (257-00018) or equivalent. 3. Road test the vehicle for 15 minutes and record the vibration frequency. a. If the vibration goes away during the test drive, discontinue this procedure. The concern is due to temporary tire flat spotting which is a normal tire condition. Refer to WSM, Section 204-04. b. If the vibration remains and the vibration frequency is within the range of 27-33 Hz proceed to Step 4. c. If the vibration frequency not within the range of 27-33 Hz, do not continue with this procedure. Follow normal WSM diagnostic. Refer to WSM, Section 100-04. 4. Install a revised steering wheel damper. a. Remove steering wheel. Refer to the WSM, Section 211-04. b. Remove the trim cover from the rear of the steering wheel. c. Remove the three (3) damper bracket screws from the steering wheel and remove steering damper. (Figure 1) d. Attach revised steering wheel damper using existing screws. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 10-18-8 > Sep > 10 > Steering - Steering Wheel Nibble In Cold Temps > Page 4773 e. Install steering wheel trim cover and steering wheel. Refer to the WSM, Section 211-04. Parts Block 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 101808A 2008-2010 Escape, 0.7 Hr. Mariner: Includes Time To Install Diagnostic Equipment And Road Test To Correct Flat Spots On Tires. (Do Not Use With Any Other Labor Operations) 101808B 2008-2010 Escape, 1.3 Hrs. Mariner: Includes Time To Install Diagnostic Equipment And Road Test To Correct Flat Spots On Tires, Condition Still Present Install The Revised Steering Wheel Damper (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 4R602 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations > Steering Wheel/Audio Control Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations > Steering Wheel/Audio Control Switch > Page 4776 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations > Page 4777 Steering Wheel: Service and Repair Steering Wheel Removal and Installation 1. Remove the driver air bag module. For additional information, refer to Air Bag Systems. 2. Disconnect the steering wheel switch electrical connector from the clockspring. - Detach the steering wheel switch wiring from the retainers and position the wires aside. 3. Remove the steering wheel bolt. - To install, tighten to 40 Nm (30 lb-ft). 4. NOTICE: Do not allow the Steering Wheel Puller to damage the steering wheel switch wires and connector while removing the steering wheel. Using the Steering Wheel Puller, remove the steering wheel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations > Page 4778 5. Tape the clockspring center rotor to the outer housing to keep it from rotating. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Tie Rod End - Inner Tie Rod: Service and Repair Tie Rod End - Inner Tie Rod End - Inner Removal and Installation 1. Remove the wheel and tire. 2. Turn the steering wheel fully in the direction of the inner tie-rod end that is being removed. 3. Loosen the tie-rod end jam nut. - To install, tighten to 40 Nm (30 lb-ft). 4. Remove and discard the outer tie-rod end nut. - To install, tighten the new nut to 80 Nm (59 lb-ft). 5. Using the Ball Joint Separator, separate the outer tie-rod end from the wheel knuckle and remove the tie rod. 6. Remove the tie-rod end jam nut. 7. Remove and discard the boot clamps and the steering gear boot. 8. Using a suitable tool, hold the steering gear rack. 9. Using a suitable tool, remove the inner tie-rod end. - To install, tighten to 90 Nm (66 lb-ft). 10. NOTE: Using a suitable tool, hold the steering gear rack while tightening the inner tie rod. To install, reverse the removal procedure. 11. Check and, if necessary, adjust the front toe. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Tie Rod End - Inner > Page 4783 Tie Rod: Service and Repair Tie Rod End - Outer Tie Rod End - Outer Removal and Installation 1. NOTE: RH side shown, LH side similar. Remove the wheel and tire. 2. Loosen the tie-rod end jam nut. - To install, tighten to 40 Nm (30 lb-ft). 3. Remove and discard the outer tie-rod end nut. - To install, tighten the new nut to 80 Nm (59 lb-ft). 4. Using the Ball Joint Separator, separate the outer tie-rod end from the front wheel knuckle. 5. Remove the outer tie-rod end. 6. To install, reverse the removal procedure. - Check and, if necessary, adjust the front toe. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Ball Joint Deflection Lower................................................................................................................... ..................................................................................0-0.2 mm (0-0.008 in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Steering/Suspension - Control Arm Bushing Inspection > Page 4793 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Steering/Suspension - Control Arm Bushing Inspection > Page 4794 WARRANTY STATUS: Information Only Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > Customer Interest for Front Cross-Member: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration Front Cross-Member: Customer Interest Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > Customer Interest for Front Cross-Member: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration > Page 4804 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration Front Cross-Member: All Technical Service Bulletins Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration > Page 4810 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > Page 4811 Front Cross-Member: By Symptom Technical Service Bulletin # 09-22-19 Date: 091116 Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > Page 4812 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Technical Service Bulletin # 09-22-19 Date: 091116 Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > Page 4813 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > Page 4814 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Technical Service Bulletin # 09-22-19 Date: 091116 Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > Page 4815 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > Page 4816 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > Customer Interest for Front Cross-Member Bushing: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration Front Cross-Member Bushing: Customer Interest Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > Customer Interest for Front Cross-Member Bushing: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration > Page 4825 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member Bushing: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration Front Cross-Member Bushing: All Technical Service Bulletins Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member Bushing: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration > Page 4831 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member Bushing: > Page 4832 Front Cross-Member Bushing: By Symptom Technical Service Bulletin # 09-22-19 Date: 091116 Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member Bushing: > Page 4833 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Technical Service Bulletin # 09-22-19 Date: 091116 Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member Bushing: > Page 4834 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member Bushing: > Page 4835 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Technical Service Bulletin # 09-22-19 Date: 091116 Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member Bushing: > Page 4836 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member Bushing: > Page 4837 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel Front Steering Knuckle: Customer Interest ABS/TCS - Clicking Noise From Left Front Wheel TSB 09-5-5 03/23/09 LEFT FRONT ABS SENSOR CONTACTING TONE RING - VEHICLES BUILT 10/21/2008-10/31/2008 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built from 10/21/2008 to 10/31/2008 may exhibit a clicking or rubbing noise from the left front wheel speed sensor and/or exhibit ABS warning light activation. The left front wheel knuckle may have been machined incorrectly allowing the wheel speed sensor to contact the tone ring. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Measure the air gap between the left front wheel speed sensor and tone ring with a feeler gage. 2. If 0.02" (0.50 mm) or more - this procedure does not apply. Continue with normal diagnostics. 3. If less than 0.02" (0.5 mm) or evidence of contact - replace the left front wheel knuckle per Workshop Manual (WSM), Section 204-01 and the left front Wheel Speed Sensor per WSM, Section 206-09. Parts Block 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 090505A 2009 Escape Hybrid, 1.3 Hrs. Mariner Hybrid: Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Be Claimed With Operations B And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505A 2009 Escape, Mariner: 1.2 Hrs. Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel > Page 4846 Be Claimed With Operations B And/Or C (Do Not Use With 2001 B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505B 2009 Escape, Mariner, 0.6 Hr. Escape Hybrid, Mariner Hybrid: Check Caster, Camber And Toe In Can Be Claimed With Operation A And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505C 2009 Escape, Mariner, 0.2 Hr. Escape Hybrid, Mariner Hybrid: Correct Toe-In Can Be Claimed With Operation A And B (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 3K186 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 09-5-5 > Mar > 09 > ABS/TCS Clicking Noise From Left Front Wheel Front Steering Knuckle: All Technical Service Bulletins ABS/TCS - Clicking Noise From Left Front Wheel TSB 09-5-5 03/23/09 LEFT FRONT ABS SENSOR CONTACTING TONE RING - VEHICLES BUILT 10/21/2008-10/31/2008 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built from 10/21/2008 to 10/31/2008 may exhibit a clicking or rubbing noise from the left front wheel speed sensor and/or exhibit ABS warning light activation. The left front wheel knuckle may have been machined incorrectly allowing the wheel speed sensor to contact the tone ring. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Measure the air gap between the left front wheel speed sensor and tone ring with a feeler gage. 2. If 0.02" (0.50 mm) or more - this procedure does not apply. Continue with normal diagnostics. 3. If less than 0.02" (0.5 mm) or evidence of contact - replace the left front wheel knuckle per Workshop Manual (WSM), Section 204-01 and the left front Wheel Speed Sensor per WSM, Section 206-09. Parts Block 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 090505A 2009 Escape Hybrid, 1.3 Hrs. Mariner Hybrid: Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Be Claimed With Operations B And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505A 2009 Escape, Mariner: 1.2 Hrs. Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 09-5-5 > Mar > 09 > ABS/TCS Clicking Noise From Left Front Wheel > Page 4852 Be Claimed With Operations B And/Or C (Do Not Use With 2001 B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505B 2009 Escape, Mariner, 0.6 Hr. Escape Hybrid, Mariner Hybrid: Check Caster, Camber And Toe In Can Be Claimed With Operation A And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505C 2009 Escape, Mariner, 0.2 Hr. Escape Hybrid, Mariner Hybrid: Correct Toe-In Can Be Claimed With Operation A And B (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 3K186 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 4853 Front Steering Knuckle: Service and Repair Wheel Knuckle Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. 1. Remove the brake disc. 2. Remove and discard the wheel hub nut. 3. Using the Front Hub Remover, separate the outer CV joint spindle from the wheel hub. 4. Remove and discard the tie-rod end nut. 5. NOTICE: Do not use a hammer to separate the tie-rod end from the wheel knuckle or damage to the wheel knuckle can result. NOTICE: Do not damage the tie-rod end boot while installing the Tie-Rod End Remover. Using the Tie-Rod End Remover, separate the tie rod from the wheel knuckle. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 4854 6. Remove and discard the lower ball joint bolt and nut. 7. Remove the wheel speed sensor bolt and position the sensor aside. 8. Separate the lower ball joint from the wheel knuckle. 9. Remove the 2 strut-to-knuckle nuts, bolts and the wheel knuckle. - Discard the nuts and bolts. Installation 1. Position the wheel knuckle and install the 2 new strut-to-knuckle bolts and nuts. - Tighten to 115 Nm (85 lb-ft). 2. Position and align the ball joint stud into the wheel knuckle. 3. Install the new lower ball joint bolt and nut. - To install, tighten to 63 Nm (46 lb-ft). 4. Install the wheel speed sensor and the bolt. - Tighten to 9 Nm (80 lb-in). 5. Position the tie-rod end into the wheel knuckle and install the new tie-rod end nut. - Tighten to 80 Nm (59 lb-ft). 6. Using the Halfshaft Installer, install the halfshaft into the wheel hub. 7. Install the brake disc. 8. NOTICE: Do not tighten the front wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied. NOTE: Apply the brake to keep the halfshaft from rotating. Install the new front wheel hub nut. - Tighten to 300 Nm (221 lb-ft). 9. Check and, if necessary, align the front end. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair Wheel Knuckle - All Wheel Drive (AWD) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 4858 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 4859 Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. 1. Remove the wheel and tire. 2. NOTE: Apply the brake to keep the halfshaft from rotating. Remove and discard the wheel hub nut. 3. Remove the brake drum. 4. Using the Front Hub Remover or equivalent, separate the CV joint from the wheel hub. 5. NOTICE: Do not use a hammer to separate the outer Constant Velocity (CV) joint from the wheel hub. Damage to the threads and internal outer CV joint components may result. Using the Front Hub Remover or equivalent and the Impact Slide Hammer or equivalent, separate the outer CV joint from the wheel hub. 6. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle after removing the wheel hub. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 4860 Using a suitable press and the Pinion Bearing Cone Remover or equivalent, press the inner bearing race from the wheel knuckle. 7. Remove the brake shoes. 8. Remove the parking brake cable bracket-to-control arm bolt. 9. Unclip the wheel speed harness retainer from the parking brake cable and disconnect the cable from the brake backing plate. 10. Remove the wheel speed sensor bolt and the 2 wheel speed sensor harness bolts. 11. Disconnect the wheel speed sensor from the wheel knuckle, and position the sensor and harness aside. 12. Remove the stabilizer bar link lower nut and disconnect the link from the wheel knuckle. - Discard the nut. 13. Remove the coil spring. For additional information, refer to Spring See: Suspension Spring ( Coil / Leaf )/Service and Repair/Removal and Replacement/Rear Suspension. 14. Remove and discard the lower ball joint nut. 15. Index-mark the notch on the cam nut adjustment cam. 16. Remove and discard the wheel knuckle bolt and cam nut. 17. Remove the wheel knuckle. 18. Remove the wheel bearing. For additional information, refer to Wheel Bearing - All Wheel Drive (AWD) See: Wheel Bearing/Service and Repair/Rear Suspension. Installation 1. Install the wheel bearing. For additional information, refer to Wheel Bearing - All Wheel Drive (AWD) See: Wheel Bearing/Service and Repair/Rear Suspension. 2. NOTICE: The joint area must be free of foreign material to make sure of correct clamping. NOTE: Align the notch on the cam nut with the index marks. NOTE: Do not tighten the wheel knuckle bolt at this time. Position the halfshaft into the wheel hub and install the wheel knuckle. Hold the cam nut stationary and loosely install a new wheel knuckle bolt and cam nut. 3. Position the lower ball joint into the wheel knuckle and install the new lower ball joint nut. - Tighten to 63 Nm (46 lb-ft). 4. Install the coil spring. For additional information, refer to Spring See: Suspension Spring ( Coil / Leaf )/Service and Repair/Removal and Replacement/Rear Suspension. 5. Connect the stabilizer bar link and install the nut. - Tighten to 55 Nm (41 lb-ft). 6. Position the wheel speed sensor harness and the sensor. 7. Install the wheel speed sensor bolt and the 2 wheel speed sensor harness bolts. - Tighten the bolts to 9 Nm (80 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 4861 8. Connect the parking brake cable to the brake backing plate and install the parking brake cable bracket bolt. - Tighten to 23 Nm (17 lb-ft). 9. Install the brake shoes and the brake drum. 10. Using the Halfshaft Installer, install the halfshaft into the wheel hub. 11. NOTE: Apply the brake to keep the halfshaft from rotating. Install a new wheel hub nut. - Tighten to 290 Nm (214 lb-ft). 12. Bleed the brake system. 13. With the weight of the vehicle on the wheel and tire, tighten the wheel knuckle bolt to 125 Nm (92 lb-ft). 14. Check and, if necessary, align the rear end. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair Stabilizer Bushing: Service and Repair Stabilizer Bar Bushing Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. NOTICE: When installing the stabilizer bar bushings, make sure the bushings are correctly oriented with the bushing flanges in the up position and the bushing split pointing to the front of the vehicle. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 2 stabilizer bar bushing bracket bolts and the stabilizer bar bushing bracket. - Discard the bolts. - To install, tighten the new bolts to 70 Nm (52 lb-ft). 3. NOTE: Inspect the stabilizer bar bushing for wear. If necessary, install a new part. Remove the stabilizer bar bushing. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 09-24-2 > Dec > 09 > Steering/Suspension - Front End Click/Pop On Bumps Stabilizer Link: Customer Interest Steering/Suspension - Front End Click/Pop On Bumps TSB 09-24-2 12/14/09 CLICK/POP NOISE FROM FRONT STABILIZER BAR END LINK AREA WHEN DRIVING OVER BUMPS - BUILT ON OR BEFORE 10/9/2009 FORD: 2005-2010 Escape MERCURY: 2005-2010 Mariner ISSUE Some 2005-2010 Escape, Escape Hybrid, Mariner and 2006-2010 Mariner Hybrid vehicles built on or before 10/9/2009 may exhibit a click/pop noise from the front end when going over bumps. This may be due to the stabilizer bar end link to strut (upper) attachment. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE 1. Using chassis ears, can the click/pop noise be isolated to the stabilizer bar end links? a. No - Do not continue with this procedure. Follow normal Workshop Manual (WSM), Section 204-00 diagnostics. b. Yes - Proceed to Step 2. 2. Inspect the stabilizer bar end link to strut (upper) attachment nuts for signs of looseness. Is any evidence present of loose upper nuts? a. No - Replace stabilizer bar end links and install revised upper nuts per WSM, Section 204-01. NOTE THE REVISED, TALLER NUTS CANNOT BE INSTALLED ON THE STABILIZER BAR END LINK LOWER ATTACHMENT. b. Yes - Remove and replace both upper nuts with revised, taller nuts per WSM, Section 204-01. Torque to 46 lb-ft (63 N.m). It is not necessary to replace the stabilizer bar end link. Parts Block 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 092402A 2005-2010 Escape, 1.1 Hrs. Mariner, Escape Hybrid, 2006-2010 Mariner Hybrid: Diagnose With Chassis Ears And Road Test, Inspect Stabilizer Bar End Links, Replace Four (4) Stabilizer End Link Nuts Or Stabilizer Bar End Links (Do Not Use With Any Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 09-24-2 > Dec > 09 > Steering/Suspension - Front End Click/Pop On Bumps > Page 4874 Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5K483 24 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 09-24-2 > Dec > 09 > Steering/Suspension - Front End Click/Pop On Bumps Stabilizer Link: All Technical Service Bulletins Steering/Suspension - Front End Click/Pop On Bumps TSB 09-24-2 12/14/09 CLICK/POP NOISE FROM FRONT STABILIZER BAR END LINK AREA WHEN DRIVING OVER BUMPS - BUILT ON OR BEFORE 10/9/2009 FORD: 2005-2010 Escape MERCURY: 2005-2010 Mariner ISSUE Some 2005-2010 Escape, Escape Hybrid, Mariner and 2006-2010 Mariner Hybrid vehicles built on or before 10/9/2009 may exhibit a click/pop noise from the front end when going over bumps. This may be due to the stabilizer bar end link to strut (upper) attachment. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE 1. Using chassis ears, can the click/pop noise be isolated to the stabilizer bar end links? a. No - Do not continue with this procedure. Follow normal Workshop Manual (WSM), Section 204-00 diagnostics. b. Yes - Proceed to Step 2. 2. Inspect the stabilizer bar end link to strut (upper) attachment nuts for signs of looseness. Is any evidence present of loose upper nuts? a. No - Replace stabilizer bar end links and install revised upper nuts per WSM, Section 204-01. NOTE THE REVISED, TALLER NUTS CANNOT BE INSTALLED ON THE STABILIZER BAR END LINK LOWER ATTACHMENT. b. Yes - Remove and replace both upper nuts with revised, taller nuts per WSM, Section 204-01. Torque to 46 lb-ft (63 N.m). It is not necessary to replace the stabilizer bar end link. Parts Block 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 092402A 2005-2010 Escape, 1.1 Hrs. Mariner, Escape Hybrid, 2006-2010 Mariner Hybrid: Diagnose With Chassis Ears And Road Test, Inspect Stabilizer Bar End Links, Replace Four (4) Stabilizer End Link Nuts Or Stabilizer Bar End Links (Do Not Use With Any Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 09-24-2 > Dec > 09 > Steering/Suspension - Front End Click/Pop On Bumps > Page 4880 Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5K483 24 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Page 4881 Stabilizer Link: Service and Repair Stabilizer Bar Link Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. NOTICE: Do not use power tools to remove or install the stabilizer bar link nuts. Damage to the stabilizer bar link ball joints and boots may occur. NOTICE: Do not hold the stabilizer bar link boot with any tool or damage to the boot may occur. NOTE: The stabilizer bar links are designed with low friction ball joints that have a low breakaway torque. NOTE: When installing the stabilizer link to the stabilizer bar, make sure the stabilizer bar is perpendicular to the stabilizer link when tightening the link nut or the link nut may not seat properly. 1. Remove the wheel and tire. 2. NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or installing the stabilizer bar link nut. Remove and discard the upper stabilizer bar link nut. - To install, tighten the new nut to 63 Nm (46 lb-ft). 3. NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or installing the stabilizer link nut. Remove and discard the lower stabilizer bar link nut. - To install, tighten the new nut to 63 Nm (46 lb-ft). 4. NOTE: Inspect the stabilizer bar link ball joints and boots for wear. If necessary, install new parts. Remove the stabilizer bar link. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) 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 4891 (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 (L4-2.5L Hybrid (2009)) 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 4892 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 (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) 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 4898 (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 (L4-2.5L Hybrid (2009)) 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 4899 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 4900 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 4901 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 4902 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 4903 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 4904 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 4905 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 4906 Front Subframe: Service and Repair SUBFRAME - FRONT Special Tool(s) Removal and Installation NOTE: Escape All-Wheel Drive (AWD) shown, all other vehicles similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 4907 Escape All-Wheel Drive (AWD) Shown, All Other Vehicles Similar NOTE: Escape and Mariner only. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 4908 Escape And Mariner Only NOTE: Escape Hybrid only. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 4909 Escape Hybrid Only All vehicles NOTICE: Suspension and subframe fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 4910 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Turn the wheels to the straight ahead position and remove the key. Hybrid vehicles 3. Disconnect the high-voltage traction battery. For additional information, refer to Hybrid Drive Systems. 4. Remove the rear transmission insulator and retainer. All vehicles 5. Remove the front tires. 6. NOTICE: - Do not reuse the Constant Velocity (CV) joint bolts and washers. Install new bolts and washers or damage to the vehicle may occur. - Do not reuse the bolts and cap straps for the center U-joint. Install new bolts and cap straps or damage to the vehicle may occur. NOTE: Index-mark the front driveshaft to the center bearing. Remove the front driveshaft, if equipped. Remove the 6 front driveshaft-to-transfer case bolts and washers. Discard the bolts and washers. To install, tighten to 37 Nm (27 lb-ft). - Remove the 4 U-joint cap strap bolts and 2 cap straps and remove the front driveshaft. Discard the U-joint cap strap bolts and cap straps. To install, tighten to 23 Nm (17 lb-ft). 7. Remove the 4 bolts (2 each side) and the lateral support crossmember. - To install, tighten to 115 Nm (85 lb-ft). 8. Remove the exhaust flexible pipe (2.3L) or the dual converter Y-pipe (3.0L). 9. Remove the 6 bolts and the scrivet from the LH splash shield and remove the splash shield. 10. Remove the engine support crossmember front insulator bolt. - To install, tighten to 115 Nm (85 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 4911 11. Remove the 2 engine support crossmember bolts. - To install, tighten to 90 Nm (66 lb-ft). Hybrid vehicles only 12. Remove the 2 bolts from the lower transmission insulator and retainer bracket. All vehicles 13. Remove the nut and the engine support crossmember. Discard the nut. - To install, tighten to 175 Nm (129 lb-ft). All vehicles except hybrid 14. Remove the rear transaxle support isolator through bolt. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 4912 - To install, tighten to 115 Nm (85 lb-ft). All vehicles 15. Remove the power steering coupler bolt. Discard the bolt. - To install, tighten to 63Nm (46 lb-ft). 16. Remove the 2 outer tie-rod end nuts. Discard the nuts. - To install, tighten to 55 Nm (41 lb-ft). 17. Using the Tie-Rod End Remover, separate the tie rod from the wheel knuckle. 18. NOTE: Use the hex-holding fixture to prevent the ball stud from turning while removing and installing the stabilizer link nut. Remove the 2 lower stabilizer bar link nuts. Discard the nuts. To install, tighten to 55 Nm (41 lb-ft). 19. Remove the 2 lower control arm ball joint pinch bolt nuts and pinch bolts. Discard the nuts and the bolts. - To install, tighten to 63 Nm (46 lb-ft). 20. Using a suitable lift, support the front subframe. 21. NOTE: - Do not allow the front subframe rear bolts to come out of the lower control arm bushing. - When installing the front subframe rear bolts, make sure both of the front subframe rear bolts are fully engaged in their cage nuts before tightening to specification. Loosen the 2 front subframe rear bolts. To install, tighten to 175 Nm (129 lb-ft). 22. Remove the 2 front subframe nuts. - To install, tighten to 150 Nm (111 lb-ft). 23. 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 front subframe. 24. To install, reverse the removal procedure. - Transfer the components as necessary. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) 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 4921 (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 (L4-2.5L Hybrid (2009)) 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 4922 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 (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) 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 4928 (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 (L4-2.5L Hybrid (2009)) 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 4929 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 (L4-2.5L Hybrid (2009)) 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 4930 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 (L4-2.5L Hybrid (2009)) 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 4931 (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 (L4-2.5L Hybrid (2009)) 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 4932 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 (L4-2.5L Hybrid (2009)) 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 4933 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 (L4-2.5L Hybrid (2009)) 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 4934 (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 (L4-2.5L Hybrid (2009)) 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 4935 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 (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) 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 4944 (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 (L4-2.5L Hybrid (2009)) 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 4945 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 (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) 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 4951 (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 (L4-2.5L Hybrid (2009)) 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 4952 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 4953 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 4954 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 4955 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 4956 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 4957 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 4958 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 4959 Rear Subframe: Service and Repair SUBFRAME - REAR Subframe - Rear Removal All vehicles 1. NOTICE: Suspension and subframe fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. With the vehicle in NEUTRAL, position it on a hoist. Vehicles with all All-Wheel Drive (AWD) 2. Remove the rear axle assembly. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 4960 All vehicles 3. Remove the rear stabilizer bar link upper nuts. 4. Remove the 4 bolts and position the 4 rear control arms aside. 5. Remove and discard the exhaust hanger from the subframe. 6. With an assistant, remove the 4 bolts and the rear subframe. Installation All vehicles 1. With an assistant, position the rear subframe and install the bolts. - To install, tighten the rear bolts to 115 Nm (85 lb-ft). - To install, tighten the front bolts to 115 Nm (85 lb-ft). 2. Install a new exhaust hanger on the subframe. 3. NOTE: The vehicle must be at ride height before tightening the bolts. Position the 4 rear control arms into the subframe. Loosely install the bolts. 4. Install the rear stabilizer bar link upper nuts. - Tighten to 48 Nm (35 lb-ft). Vehicles with AWD 5. Install the rear axle assembly. All vehicles 6. Tighten the 4 rear control arms bolts. - Tighten to 115 Nm (85 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 4961 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) 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 4970 (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 (L4-2.5L Hybrid (2009)) 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 4971 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 (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) 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 4977 (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 (L4-2.5L Hybrid (2009)) 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 4978 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 (L4-2.5L Hybrid (2009)) 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 4979 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 (L4-2.5L Hybrid (2009)) 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 4980 (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 (L4-2.5L Hybrid (2009)) 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 4981 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 (L4-2.5L Hybrid (2009)) 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 4982 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 (L4-2.5L Hybrid (2009)) 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 4983 (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 (L4-2.5L Hybrid (2009)) 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 4984 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement Suspension Spring ( Coil / Leaf ): Removal and Replacement Front Suspension Strut and Spring Assembly Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. NOTE: LH side shown, RH side similar. 1. NOTE: Verify the steering wheel is in the unlocked position before removal. Remove the wheel and tire. 2. Remove the brake jounce hose clip. 3. Pull the brake jounce hose downward slightly to remove the hose from the bracket and position the brake jounce hose aside. 4. Remove the wheel speed sensor harness bolt. 5. NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or installing the stabilizer bar link nut. Remove and discard the upper stabilizer bar link nut. 6. Remove and discard the 2 strut-to-knuckle nuts and bolts. 7. NOTE: Reference mark the 4 strut upper bushing plate nuts. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 4989 Remove and discard the 4 strut upper bushing nuts. 8. NOTICE: Do not allow the axle shaft to move outboard. Over-extension of the tripod constant velocity (CV) joint can result in the separation of internal parts, causing failure of the axle shaft. Remove the strut and spring assembly. 9. For additional information on the disassembly and assembly of the strut and spring assembly, refer to Strut and Spring Assembly See: Suspension Strut / Shock Absorber/Service and Repair/Overhaul. Installation 1. Position the strut and spring assembly upper mounting plate into the inner fender. 2. Align the 4 new strut upper bushing nuts to the reference marks. - Tighten to 47 Nm (35 lb-ft). 3. Install the 2 new strut-to-knuckle bolts and nuts. - Tighten to 115 Nm (85 lb-ft). 4. Install the new upper stabilizer bar link nut. - Tighten to 63 Nm (46 lb-ft). 5. Install the wheel speed sensor harness bolt. - Tighten to 15 Nm (133 lb-in). 6. Position the brake jounce hose to the bracket and install the brake jounce hose clip. 7. Check the front end alignment and adjust as necessary. Rear Suspension Spring NOTE: All-Wheel Drive (AWD) vehicle shown, Front Wheel Drive (FWD) vehicle similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 4990 Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. 1. Remove the wheel and tire. 2. Remove the brake hose bracket-to-wheel knuckle bolt. 3. Disconnect the brake tube from the wheel cylinder and position the brake tube and bracket assembly aside. 4. Using a suitable jackstand, support the wheel knuckle. 5. Remove and discard the shock absorber lower nut, washer and bolt. 6. Remove the upper arm. For additional information, refer to Upper Arm See: Control Arm/Service and Repair/Rear Suspension/Upper Arm. 7. Loosen the lower arm inner bolt. 8. NOTE: Note the position of the coil spring insulators and coil spring for installation. Using the jackstand, carefully lower the wheel knuckle. 9. Remove the coil spring. Installation 1. Align the coil spring and coil spring insulators to the previously noted position. 2. Using a suitable jackstand, carefully raise the wheel knuckle. 3. Install the new shock absorber lower bolt, washer and nut. - Tighten to 175 Nm (129 lb-ft). 4. Install the upper arm. For additional information, refer to Upper Arm See: Control Arm/Service and Repair/Rear Suspension/Upper Arm. 5. Connect the brake tube fitting to the wheel cylinder. - Tighten to 17 Nm (150 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 4991 6. Install the brake tube bracket bolt. - Tighten to 22 Nm (16 lb-ft). 7. Install the brake hose bracket-to-wheel knuckle bolt. - Tighten to 22 Nm (16 lb-ft). 8. Bleed the rear wheel cylinder. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 4992 Suspension Spring ( Coil / Leaf ): Overhaul Front Strut and Spring Assembly Disassembly and Assembly NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. 1. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. NOTE: Do not use an impact wrench on the strut rod nut. Mount the strut and spring assembly in a suitable spring compressor. 2. Compress the coil spring enough to relieve the tension on the strut assembly. 3. Remove and discard the strut rod nut. - To assemble, tighten the new nut to 103 Nm (76 lb-ft). 4. Remove the strut. 5. Remove the lower coil spring insulator. 6. Remove the coil spring. 7. Remove the upper coil spring insulator. 8. NOTE: During assembly, assemble the bearing plate to the strut so the arrow on the bearing plate points to the outboard side of the vehicle when Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 4993 the strut is installed. Remove the bearing plate. 9. Remove the bearing. 10. Remove the strut upper bushing. 11. Remove the dust boot and the bumper. 12. To assemble, reverse the disassembly procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises Suspension Strut / Shock Absorber: Customer Interest Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises TSB 09-6-5 04/06/09 NOISE - FRONT STRUT AREA FORD: 2001-2009 Escape 2005-2009 Escape Hybrid MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2001-2009 Escape, 2005-2009 Escape Hybrid, Mariner and 2006-2009 Mariner Hybrid vehicles may exhibit a pop, rub, grunt, squeak, and/or creak noise from the front strut area during slow, lock-to-lock turns such as parking maneuvers. Vehicles built on or before 1/13/2009 may also exhibit a clunk, crunch, thump, and/or knocking noise from the front strut area while driving over a series of bumps and/or rough roads. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Using chassis ears on the front strut mounts is pop, rub, grunt, squeak, creak, clunk, crunch, thump, and/or knocking noise present from the front strut area during slow parking lot type maneuvers? a. No - Procedure does not apply, proceed with normal Workshop Manual (WSM), Section 204-00 diagnostics. b. Yes on turns - Boot may be binding, go to Step 2 Dust Boot Greasing Procedure. c. Yes over bumps (built on or before 1/13/2009) - Go to Step 3 Dust Boot Replacement Procedure and install new dust boot designed for this concern. d. Yes over bumps (built after 1/13/09) - Procedure does not apply. Proceed with normal WSM, Section 204-00 diagnostics. 2. Dust Boot Greasing Procedure. a. Raise the vehicle per WSM, Section 100-02. b. Reach through the spring and pull the strut dust boot and jounce bumper assembly straight down, out of the upper spring seat. c. Apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound. (Figure 1) (1) To the entire length of the chrome strut rod above the jounce bumper and 360 degrees around the rod. (2) To the top and sides of the uppermost part of the dust cover. d. Raise dust cover so that jounce bumper is accessible and apply 360 degrees to the jounce bumper itself. e. Slide the dust cover and jounce bumper upward into its original location on the strut. f. Repeat the procedure on the other side of the vehicle. 3. Dust Boot Replacement Procedure (vehicles built on/before 1/13/2009). a. Remove front strut per WSM, Section 204-01. b. Disassemble front strut and replace dust boot with latest level part per WSM, Section 204-01. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises > Page 5002 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises > Page 5003 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises TSB 09-6-5 04/06/09 NOISE - FRONT STRUT AREA FORD: 2001-2009 Escape 2005-2009 Escape Hybrid MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2001-2009 Escape, 2005-2009 Escape Hybrid, Mariner and 2006-2009 Mariner Hybrid vehicles may exhibit a pop, rub, grunt, squeak, and/or creak noise from the front strut area during slow, lock-to-lock turns such as parking maneuvers. Vehicles built on or before 1/13/2009 may also exhibit a clunk, crunch, thump, and/or knocking noise from the front strut area while driving over a series of bumps and/or rough roads. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Using chassis ears on the front strut mounts is pop, rub, grunt, squeak, creak, clunk, crunch, thump, and/or knocking noise present from the front strut area during slow parking lot type maneuvers? a. No - Procedure does not apply, proceed with normal Workshop Manual (WSM), Section 204-00 diagnostics. b. Yes on turns - Boot may be binding, go to Step 2 Dust Boot Greasing Procedure. c. Yes over bumps (built on or before 1/13/2009) - Go to Step 3 Dust Boot Replacement Procedure and install new dust boot designed for this concern. d. Yes over bumps (built after 1/13/09) - Procedure does not apply. Proceed with normal WSM, Section 204-00 diagnostics. 2. Dust Boot Greasing Procedure. a. Raise the vehicle per WSM, Section 100-02. b. Reach through the spring and pull the strut dust boot and jounce bumper assembly straight down, out of the upper spring seat. c. Apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound. (Figure 1) (1) To the entire length of the chrome strut rod above the jounce bumper and 360 degrees around the rod. (2) To the top and sides of the uppermost part of the dust cover. d. Raise dust cover so that jounce bumper is accessible and apply 360 degrees to the jounce bumper itself. e. Slide the dust cover and jounce bumper upward into its original location on the strut. f. Repeat the procedure on the other side of the vehicle. 3. Dust Boot Replacement Procedure (vehicles built on/before 1/13/2009). a. Remove front strut per WSM, Section 204-01. b. Disassemble front strut and replace dust boot with latest level part per WSM, Section 204-01. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises > Page 5009 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises > Page 5010 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Catalytic Converter Mounting Gasket: All Technical Service Bulletins Engine Controls/Exhaust MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 5016 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 5022 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement Suspension Strut / Shock Absorber: Removal and Replacement Front Suspension Front Strut and Spring Assembly Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. NOTE: LH side shown, RH side similar. 1. NOTE: Verify the steering wheel is in the unlocked position before removal. Remove the wheel and tire. 2. Remove the brake jounce hose clip. 3. Pull the brake jounce hose downward slightly to remove the hose from the bracket and position the brake jounce hose aside. 4. Remove the wheel speed sensor harness bolt. 5. NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or installing the stabilizer bar link nut. Remove and discard the upper stabilizer bar link nut. 6. Remove and discard the 2 strut-to-knuckle nuts and bolts. 7. NOTE: Reference mark the 4 strut upper bushing plate nuts. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5025 Remove and discard the 4 strut upper bushing nuts. 8. NOTICE: Do not allow the axle shaft to move outboard. Over-extension of the tripod constant velocity (CV) joint can result in the separation of internal parts, causing failure of the axle shaft. Remove the strut and spring assembly. 9. For additional information on the disassembly and assembly of the strut and spring assembly, refer to Strut and Spring Assembly See: Overhaul. Installation 1. Position the strut and spring assembly upper mounting plate into the inner fender. 2. Align the 4 new strut upper bushing nuts to the reference marks. - Tighten to 47 Nm (35 lb-ft). 3. Install the 2 new strut-to-knuckle bolts and nuts. - Tighten to 115 Nm (85 lb-ft). 4. Install the new upper stabilizer bar link nut. - Tighten to 63 Nm (46 lb-ft). 5. Install the wheel speed sensor harness bolt. - Tighten to 15 Nm (133 lb-in). 6. Position the brake jounce hose to the bracket and install the brake jounce hose clip. 7. Check the front end alignment and adjust as necessary. Rear Suspension Rear Shock Absorber Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5026 1. Remove the rear quarter trim panel. 2. Remove the wheel and tire. 3. Using a suitable jackstand, support the rear suspension. 4. Remove and discard the upper shock absorber nut and bushing assembly. - To install, tighten the new nut and bushing assembly to 40 Nm (30 lb-ft). 5. Remove and discard the lower shock absorber nut, washer and bolt. - To install, tighten the new nut to 175 Nm (129 lb-ft). 6. Remove the shock absorber. 7. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5027 Suspension Strut / Shock Absorber: Overhaul Front Strut and Spring Assembly Disassembly and Assembly NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. 1. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. NOTE: Do not use an impact wrench on the strut rod nut. Mount the strut and spring assembly in a suitable spring compressor. 2. Compress the coil spring enough to relieve the tension on the strut assembly. 3. Remove and discard the strut rod nut. - To assemble, tighten the new nut to 103 Nm (76 lb-ft). 4. Remove the strut. 5. Remove the lower coil spring insulator. 6. Remove the coil spring. 7. Remove the upper coil spring insulator. 8. NOTE: During assembly, assemble the bearing plate to the strut so the arrow on the bearing plate points to the outboard side of the vehicle when Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5028 the strut is installed. Remove the bearing plate. 9. Remove the bearing. 10. Remove the strut upper bushing. 11. Remove the dust boot and the bumper. 12. To assemble, reverse the disassembly procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Wheel Bearing and Wheel Hub Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. NOTE: If removing the wheel hub, a new wheel bearing must be installed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5033 1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle See: Front Steering Knuckle/Service and Repair. 2. Using the Pinion Bearing Cone Remover, press the wheel hub from the wheel bearing. 3. 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 Pinion Bearing Cone Remover, press the inner wheel bearing race from the wheel hub. 4. Remove the snap ring. 5. Using the Pinion Bearing Cone Remover, Wheel Bearing Adapter and Handle, press the outer wheel bearing race from the wheel knuckle. Installation 1. Position the wheel knuckle in a vise. 2. NOTE: Step Plate 205-278 is not seen in place. It is located behind the wheel knuckle. Using the Pinion Bearing Cup Replacer and the 2 Step Plates, install the wheel bearing into the wheel knuckle. 3. Install the snap ring. 4. Using the Pinion Bearing Cone Remover, press the wheel hub into the wheel bearing. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5034 5. Install the wheel knuckle. For additional information, refer to Wheel Knuckle See: Front Steering Knuckle/Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5035 Wheel Bearing: Service and Repair Rear Suspension Wheel Bearing - All Wheel Drive (AWD) Removal Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5036 1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle - All Wheel Drive (AWD) See: Rear Knuckle/Service and Repair. 2. Remove the wheel bearing snap ring. 3. Remove the 4 bolts and the brake drum backing plate. 4. Position the wheel knuckle on a suitable press. - Using the PTO Driven Gear Oil Seal Installer, the Handle and the Pinion Bearing Cone Remover or equivalent, position the wheel knuckle on a suitable press and press the wheel bearing from the wheel knuckle. Installation 1. Using the Rear Axle Drawbar, Bearing Cup Replacer and Differential Bearing Cup Replacer, install a new wheel bearing into the wheel knuckle. 2. Install the new wheel bearing snap ring. 3. Install the 4 bolts and the brake drum backing plate. - Tighten to 85 Nm (63 lb-ft). 4. Using the Halfshaft Installer and Receiver Adapter, install the wheel hub into the wheel bearing. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5037 5. Install the wheel knuckle. For additional information, refer to Wheel Knuckle - All Wheel Drive (AWD) See: Rear Knuckle/Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Rear Install the new wheel hub nut Tighten to..................................................................................... ..............................................................................................................290 Nm (214 lb-ft). Front Install the new wheel hub nut Tighten to..................................................................................... ..............................................................................................................300 Nm (221 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation Jacking and Lifting WARNING: When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle movement. Failure to follow these instructions may result in serious personal injury. WARNING: Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions may result in serious personal injury. WARNING: Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure to follow this instruction may result in serious personal injury. WARNING: Vehicle may have multiple drive wheels. Do not use engine to power the driveline unless all drive wheels are elevated off the ground. Drive wheels in contact with ground could cause unexpected vehicle movement. Failure to follow this instruction may result in serious personal injury. WARNING: Position the hoist lift arms as shown in the illustration. Incorrect positioning could result in vehicle slipping or falling from the hoist. Failure to follow this instruction may result in serious personal injury. NOTICE: The jack provided with the vehicle is intended to be used in an emergency for changing a deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other purpose. NOTICE: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on lift without first checking for possible interference. NOTICE: Damage to the rear tire air deflector, suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Front and Rear - Jacking and Lifting Points Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Tire Monitoring System/Testing and Inspection/Programming and Relearning. NOTE: The Tire Pressure Monitoring System (TPMS) Training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. NOTE: Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place at the valve stem. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall at the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall at the valve stem and press and release the test button to train the RF tire pressure sensor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 5051 8. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 5052 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" when a vehicle is stationary to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall at the tire valve stem. 3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. This feedback may not always be present, do not rely on it to reflect the most recent pressure data. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. If the sensor still does not respond, attempt to activate the same sensor again using the customer activation tool (if available). If the sensor still fails to train, attempt to train the sensor with the vehicle doors open. Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor. Activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Testing and Inspection/Programming and Relearning. NOTE: The Tire Pressure Monitoring System (TPMS) Training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. NOTE: Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place at the valve stem. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall at the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall at the valve stem and press and release the test button to train the RF tire pressure sensor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 5058 8. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 5059 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" when a vehicle is stationary to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall at the tire valve stem. 3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. This feedback may not always be present, do not rely on it to reflect the most recent pressure data. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. If the sensor still does not respond, attempt to activate the same sensor again using the customer activation tool (if available). If the sensor still fails to train, attempt to train the sensor with the vehicle doors open. Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor. Activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Wheel Bearing and Wheel Hub Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. NOTE: If removing the wheel hub, a new wheel bearing must be installed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5064 1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle See: Steering/Front Steering Knuckle/Service and Repair. 2. Using the Pinion Bearing Cone Remover, press the wheel hub from the wheel bearing. 3. 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 Pinion Bearing Cone Remover, press the inner wheel bearing race from the wheel hub. 4. Remove the snap ring. 5. Using the Pinion Bearing Cone Remover, Wheel Bearing Adapter and Handle, press the outer wheel bearing race from the wheel knuckle. Installation 1. Position the wheel knuckle in a vise. 2. NOTE: Step Plate 205-278 is not seen in place. It is located behind the wheel knuckle. Using the Pinion Bearing Cup Replacer and the 2 Step Plates, install the wheel bearing into the wheel knuckle. 3. Install the snap ring. 4. Using the Pinion Bearing Cone Remover, press the wheel hub into the wheel bearing. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5065 5. Install the wheel knuckle. For additional information, refer to Wheel Knuckle See: Steering/Front Steering Knuckle/Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5066 Wheel Bearing: Service and Repair Rear Suspension Wheel Bearing - All Wheel Drive (AWD) Removal Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5067 1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle - All Wheel Drive (AWD) See: Suspension/Rear Knuckle/Service and Repair. 2. Remove the wheel bearing snap ring. 3. Remove the 4 bolts and the brake drum backing plate. 4. Position the wheel knuckle on a suitable press. - Using the PTO Driven Gear Oil Seal Installer, the Handle and the Pinion Bearing Cone Remover or equivalent, position the wheel knuckle on a suitable press and press the wheel bearing from the wheel knuckle. Installation 1. Using the Rear Axle Drawbar, Bearing Cup Replacer and Differential Bearing Cup Replacer, install a new wheel bearing into the wheel knuckle. 2. Install the new wheel bearing snap ring. 3. Install the 4 bolts and the brake drum backing plate. - Tighten to 85 Nm (63 lb-ft). 4. Using the Halfshaft Installer and Receiver Adapter, install the wheel hub into the wheel bearing. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5068 5. Install the wheel knuckle. For additional information, refer to Wheel Knuckle - All Wheel Drive (AWD) See: Suspension/Rear Knuckle/Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Rear Install the new wheel hub nut Tighten to..................................................................................... ..............................................................................................................290 Nm (214 lb-ft). Front Install the new wheel hub nut Tighten to..................................................................................... ..............................................................................................................300 Nm (221 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Install the 5 wheel nuts. Tighten the wheel nuts in a star pattern. Tighten to....................................... ............................................................................................................................................................1 35 Nm (100 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. 1. Remove the wheel bearing and hub. For additional information, refer to Wheel Bearing and Wheel Hub See: Wheel Bearing/Service and Repair/Front Suspension. 2. Using a suitable press, remove the wheel stud from the wheel hub. - Discard the wheel stud. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 5078 Wheel Fastener: Service and Repair Rear Suspension Wheel Studs Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. NOTICE: Never use a hammer to remove a wheel stud. Damage to the wheel hub may result. 1. Remove the brake shoes. 2. Using the C-Frame and Screw Installer/Remover, remove the wheel stud. 3. NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud serrations. Use enough washers (approximately 4) to allow the wheel stud to fully seat against the hub flange. Position the new wheel stud in the wheel hub, aligning the serrations in the wheel hub flange made by the original wheel stud. - Place approximately 4 washers over the outside end of the wheel stud and thread a standard wheel nut onto the wheel stud with the flat side Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 5079 against the washers. - Tighten the wheel nut until the wheel stud head seats against the back side of the wheel hub flange. 4. Remove the wheel nut and washers. 5. Install the brake shoes. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 10-8-6 > May > 10 > A/C - Side To Side Temperature Variations Air Door Actuator / Motor: Customer Interest A/C - Side To Side Temperature Variations TSB 10-8-6 05/10/10 CLIMATE CONTROL TEMPERATURE VARIATION FROM SIDE TO SIDE-BUILT BEFORE 12/17/2008 FORD: 2008-2009 Escape Hybrid, Escape MERCURY: 2008-2009 Mariner Hybrid, Mariner This article supersedes TSB 09-12-6 to update the Service Labor Time Standards. ISSUE Some 2008-2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built before 12/17/2008 may exhibit intermittent or erratic side to side temperature difference and/or temp fluctuation from the climate control vents. The concern may be with the temperature blend door actuator. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove temperature blend door actuator(s) per Workshop Manual (WSM), Section 412-01. 2. Inspect the 5 digit manufacturer's date code on the temperature blend door actuator. It will be the last 5 digits on the second line of manufacturer's data. The first three digits equal day of year. The last two digits equal year. (Figure 1) a. If the part number is 8L84-19E616-EA and the date code is 30708 or lower - replace the temperature blend door actuator assembly. b. If the part number is 8L84-19E616-EA and the date code is 30808 or higher - reinstall the actuator and continue with normal diagnostics per WSM, Section 412-00. c. If the part number is something other than 8L84-19E616-EA - reinstall the actuator and continue with normal diagnostics per WSM, Section 412-00. NOTE IF THE VEHICLE IS EQUIPPED WITH DUAL AUTOMATIC TEMPERATURE CONTROL (DATC), AND EITHER ONE OF THE ACTUATORS EXHIBITS THIS CONCERN AND HAS SUSPECT DATE CODE, THEN REPLACE BOTH RIGHT (RH) AND LEFT HAND (LH) ACTUATORS AS A SET. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 10-8-6 > May > 10 > A/C - Side To Side Temperature Variations > Page 5090 Parts Block 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 100806A 2008 Escape, Mariner, 2.3 Hrs. Escape Hybrid, And Mariner Hybrid: Inspect Or Replace The Right Blend Door Actuator Electronic Manual Temperature Control (EMTC) (Do Not Use With Any Other Labor Operations) 100806A 2009 Escape, Mariner, 2.7 Hrs. Escape Hybrid, And Mariner Hybrid: Inspect Or Replace The Right Blend Door Actuator Electronic Manual Temperature Control (EMTC) (Do Not Use With Any Other Labor Operations) 100806B 2009 Escape, Mariner, 2.8 Hrs Escape Hybrid, And Mariner Hybrid: Inspect Or Replace The Both Right And Left Blend Door Actuator Electronic Automatic Temperature Control (EATC) (Do Not Use With Any Other Labor Operations) 100806B 2008 Escape, Mariner, 2.4 Hrs. Escape Hybrid, And Mariner Hybrid: Inspect Or Replace The Both Right And Left Blend Door Actuator Electronic Automatic Temperature Control (EATC) (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19E616 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-8-6 > May > 10 > A/C - Side To Side Temperature Variations Air Door Actuator / Motor: All Technical Service Bulletins A/C - Side To Side Temperature Variations TSB 10-8-6 05/10/10 CLIMATE CONTROL TEMPERATURE VARIATION FROM SIDE TO SIDE-BUILT BEFORE 12/17/2008 FORD: 2008-2009 Escape Hybrid, Escape MERCURY: 2008-2009 Mariner Hybrid, Mariner This article supersedes TSB 09-12-6 to update the Service Labor Time Standards. ISSUE Some 2008-2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built before 12/17/2008 may exhibit intermittent or erratic side to side temperature difference and/or temp fluctuation from the climate control vents. The concern may be with the temperature blend door actuator. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove temperature blend door actuator(s) per Workshop Manual (WSM), Section 412-01. 2. Inspect the 5 digit manufacturer's date code on the temperature blend door actuator. It will be the last 5 digits on the second line of manufacturer's data. The first three digits equal day of year. The last two digits equal year. (Figure 1) a. If the part number is 8L84-19E616-EA and the date code is 30708 or lower - replace the temperature blend door actuator assembly. b. If the part number is 8L84-19E616-EA and the date code is 30808 or higher - reinstall the actuator and continue with normal diagnostics per WSM, Section 412-00. c. If the part number is something other than 8L84-19E616-EA - reinstall the actuator and continue with normal diagnostics per WSM, Section 412-00. NOTE IF THE VEHICLE IS EQUIPPED WITH DUAL AUTOMATIC TEMPERATURE CONTROL (DATC), AND EITHER ONE OF THE ACTUATORS EXHIBITS THIS CONCERN AND HAS SUSPECT DATE CODE, THEN REPLACE BOTH RIGHT (RH) AND LEFT HAND (LH) ACTUATORS AS A SET. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-8-6 > May > 10 > A/C - Side To Side Temperature Variations > Page 5096 Parts Block 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 100806A 2008 Escape, Mariner, 2.3 Hrs. Escape Hybrid, And Mariner Hybrid: Inspect Or Replace The Right Blend Door Actuator Electronic Manual Temperature Control (EMTC) (Do Not Use With Any Other Labor Operations) 100806A 2009 Escape, Mariner, 2.7 Hrs. Escape Hybrid, And Mariner Hybrid: Inspect Or Replace The Right Blend Door Actuator Electronic Manual Temperature Control (EMTC) (Do Not Use With Any Other Labor Operations) 100806B 2009 Escape, Mariner, 2.8 Hrs Escape Hybrid, And Mariner Hybrid: Inspect Or Replace The Both Right And Left Blend Door Actuator Electronic Automatic Temperature Control (EATC) (Do Not Use With Any Other Labor Operations) 100806B 2008 Escape, Mariner, 2.4 Hrs. Escape Hybrid, And Mariner Hybrid: Inspect Or Replace The Both Right And Left Blend Door Actuator Electronic Automatic Temperature Control (EATC) (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19E616 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Door Actuator / Motor: > 09-4-4 > Mar > 09 > Drivetrain - Fluid leak From PTU Vent Fluid - Transfer Case: All Technical Service Bulletins Drivetrain - Fluid leak From PTU Vent TSB 09-4-4 03/09/09 PTU VENT BOLT LEAK - MISDIAGNOSED AS PTU SHAFT SEAL LEAK FORD: 2005-2009 Escape Hybrid, Escape MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2005-2009 Escape, Mariner, Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit a leak from the power transfer unit (PTU) vent tube bolt. This may be misdiagnosed as a PTU link shaft seal leak. Please verify leak origin and tighten PTU vent tube bolt, before replacing parts. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the PTU fill plug and check fluid level per Workshop Manual (WSM), Section 308-07B. NOTE THE FLUID LEVEL MUST BE EVEN WITH THE BOTTOM OF THE FILLER HOLE WITH THE VEHICLE ON FLAT, LEVEL GROUND. 2. Inspect PTU vent tube bolt for leak. (Figure 1) a. If PTU vent tube bolt leaking - clean bolt contact sur[aces and torque bolt to 120 +/- 19 lb-in (13.5 +/- 2.1 N.m). b. If PTU vent tube bolt not leaking - continue with normal WSM, Section 308-07B diagnosis. NOTE THIS BOLT DOES NOT REQUIRE A WASHER FOR THIS APPLICATION. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Door Actuator / Motor: > 09-4-4 > Mar > 09 > Drivetrain - Fluid leak From PTU Vent > Page 5102 OPERATION DESCRIPTION TIME 090404A 2005-2009 Escape, 0.5 Hr. Mariner, Escape Hybrid, 2006-2009 Mariner Hybrid: Clean Bolt Contact Surfaces, Includes Time To Check And Adjust PTU Fluid Level DEALER CODING CONDITION BASIC PART NO. CODE 7034 24 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Door Actuator / Motor: > 09-4-4 > Mar > 09 > Drivetrain - Fluid leak From PTU Vent > Page 5108 OPERATION DESCRIPTION TIME 090404A 2005-2009 Escape, 0.5 Hr. Mariner, Escape Hybrid, 2006-2009 Mariner Hybrid: Clean Bolt Contact Surfaces, Includes Time To Check And Adjust PTU Fluid Level DEALER CODING CONDITION BASIC PART NO. CODE 7034 24 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Air Inlet Door Actuator Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Air Inlet Door Actuator > Page 5111 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Air Inlet Door Actuator > Page 5112 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Air Inlet Door Actuator > Page 5113 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Air Inlet Door Actuator > Page 5114 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Air Inlet Door Actuator Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Air Inlet Door Actuator > Page 5117 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Air Inlet Door Actuator > Page 5118 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Air Inlet Door Actuator > Page 5119 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Air Inlet Door Actuator > Page 5120 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Procedures Air Door Actuator / Motor: Procedures Auxiliary Mode Door Actuator Removal and Installation. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 2 auxiliary line floorpan bracket nuts. To install, tighten to 6 Nm (53 lb-in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Procedures > Page 5123 3. NOTE: The D-pillar bracket mill remain in place. Remove the LH D-pillar trim panel. See: Body and Frame/Interior Moulding / Trim 4. NOTE: When installing, tighten the screws on the High voltage Traction Battery (HVTB) first to make sure the duct is sealed correctly. Remove the 4 battery airflow duct screws, the 1 pin-type retainer and the battery airflow duct assembly To install, tighten 12 Nm (18 lb-in) 5. Remove the 2 auxiliary climate control fresh air inlet duct nuts ^ To install tighten to 7 Nm (62 lb-in). 6. Remove the 2 auxiliary climate control housing bolts. ^ To install tighten to 7 Nm (62 lb-in). 7. Remove the D-pillar bracket pin-type retainer. 8. Remove the D-pillar bracket upper pin-type retainer and bolt end remove the D-pillar bracket. 9. Disconnect the auxiliary airflow mode door actuator electrical connector 10. NOTE: The auxiliary climate control housing must be slightly repositioned to remove the screws. Remove the auxiliary airflow mode door Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Procedures > Page 5124 actuator screws. ^ Disconnect the rod. ^ To install, tighten to 2 Nm (18 lb-in). 11. Remove the auxiliary airflow mode door actuator 12. NOTE: The auxiliary climate control housing must be installed behind the lower portion of the D-pillar bracket. When installed correctly, the auxiliary climate control housing bolt will go through the D-pillar bracket first, then through the housing mounting location. NOTE: Before the D-pillar trim panel and LH quarter trim panel are installed, correct auxiliary mode door actuator operation can be verified by carrying out the Traction Battery Control Module (TBCM) self-test while visually verifying correct actuator operation. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Procedures > Page 5125 Air Door Actuator / Motor: Removal and Replacement Mode Door Actuator - Defrost/Panel/Floor Door Mode Door Actuator - Defrost/Panel/Floor Door Removal and Installation NOTE: The defrost/panel/floor mode door actuator can be accessed from below the LH side of the instrument panel. 1. Disconnect the defrost/panel/floor mode door actuator electrical connector. 2. Remove the 2 defrost/panel/floor mode door actuator screws. - To install, tighten to 3 Nm (27 lb-in). 3. Remove the defrost/panel/floor mode door actuator. 4. To install, reverse the removal procedure. Mode Door Actuator - Air Inlet Door Mode Door Actuator - Air Inlet Door Removal and Installation Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Procedures > Page 5126 1. Remove the heater core and evaporator core housing. For additional information, refer to Heater Core And Evaporator Core Housing See: Housing Assembly HVAC/Service and Repair/Heater Core And Evaporator Core Housing. 2. Disconnect the air inlet mode door actuator electrical connector. 3. Remove the 2 air inlet mode door actuator screws. - To install, tighten to 3 Nm (27 lb-in). 4. Remove the air inlet mode door actuator. 5. To install, reverse the removal procedure. Temperature Blend Door Actuator - RH Temperature Blend Door Actuator - RH Removal and Installation NOTE: On vehicles equipped with dual-zone Electronic Automatic Temperature Control (EATC), the RH temperature blend door actuator is used to control only the RH temperature blend door. On vehicles equipped with Electronic Manual Temperature Control (EMTC), the RH temperature blend door actuator is used to control the single temperature blend door for both sides of the vehicle. 1. Remove the upper center instrument panel finish panel. 2. Remove the passenger airbag module. For additional information, refer to Air Bag Systems. 3. Working through the passenger airbag module opening, remove the RH panel duct screw. 4. Working through the passenger airbag module opening, remove the upper RH center panel duct screw Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Procedures > Page 5127 5. NOTE: The lower RH center panel duct screw is located just below the RH lower rear corner of the Audio Control Module (ACM). Remove the lower RH center panel duct screw. 1. Detach the wire harness pin-type retainer. 2. Remove the lower RH center panel duct screw. 6. Working through the glove compartment opening, detach the wire harness pin-type retainer above the evaporator discharge air temperature sensor. 7. Disconnect the RH temperature blend door actuator electrical connector. 8. NOTICE: Use care to avoid dropping the RH temperature blend door actuator screws into the plenum chamber when removing the screws. If a screw is dropped into the plenum chamber, it may cause the airflow mode doors to jam, or may cause noise concerns. NOTE: The RH center instrument panel duct must be slightly repositioned to allow access to the RH temperature blend door actuator screws. Remove the 2 RH temperature blend door actuator screws. - To install, tighten to 3 Nm (27 lb-in). 9. Remove the RH temperature blend door actuator. 10. To install, reverse the removal procedure. Temperature Blend Door Actuator - LH Temperature Blend Door Actuator - LH Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Procedures > Page 5128 Removal and Installation NOTE: The LH temperature blend door actuator is present on dual-zone Electronic Automatic Temperature Control (EATC) vehicles to control the LH temperature blend door only. Vehicles equipped with Electronic Manual Temperature Control (EMTC) are not equipped with this actuator. For EMTC vehicles, refer to Temperature Blend Door Actuator - RH See: Temperature Blend Door Actuator - RH. 1. Disconnect the LH temperature blend door actuator electrical connector. 2. Remove the 2 LH temperature blend door actuator screws. - To install, tighten to 3 Nm (27 lb-in). 3. Remove the LH temperature blend door actuator. 4. To install, reverse the removal procedure. Auxiliary Mode Door Actuator Auxiliary Mode Door Actuator Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Procedures > Page 5129 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 2 auxiliary line floorpan bracket nuts. - To install, tighten to 6 Nm (53 lb-in). 3. NOTE: The D-pillar bracket will remain in place. Remove the LH D-pillar trim panel. 4. NOTE: When installing, tighten the screws on the High Voltage Traction Battery (HVTB) first to make sure the duct is sealed correctly. Remove the 4 battery airflow duct screws, the 1 pin-type retainer and the battery airflow duct assembly. - To install, tighten to 2 Nm (18 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Procedures > Page 5130 5. Remove the 2 auxiliary climate control fresh air inlet duct nuts. - To install, tighten to 7 Nm (62 lb-in). 6. Remove the 2 auxiliary climate control housing bolts. - To install, tighten to 7 Nm (62 lb-in). 7. Remove the D-pillar bracket pin-type retainer. 8. Remove the D-pillar bracket upper pin-type retainer and bolt and remove the D-pillar bracket. 9. Disconnect the auxiliary airflow mode door actuator electrical connector. 10. NOTE: The auxiliary climate control housing must be slightly repositioned to remove the screws. Remove the auxiliary airflow mode door actuator screws. - Disconnect the rod. - To install, tighten to 2 Nm (18 lb-in). 11. Remove the auxiliary airflow mode door actuator. 12. NOTE: The auxiliary climate control housing must be installed behind the lower portion of the D-pillar bracket. When installed correctly, the auxiliary climate control housing bolt will go through the D-pillar bracket first, then through the housing mounting location. NOTE: Before the D-pillar trim panel and LH quarter trim panel are installed, correct auxiliary mode door actuator operation can be verified by carrying out the Traction Battery Control Module (TBCM) self-test while visually verifying correct actuator operation. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents Air Duct: Customer Interest A/C - White Flakes Are Blowing From Dash Vents TSB 09-21-6 11/02/09 WHITE FLAKES COMING FROM A/C VENTS FORD: 2005-2009 Focus 2008-2010 Crown Victoria 2000-2005 Expedition, F-150 2007-2009 Edge 2008-2010 Escape Hybrid, Escape LINCOLN: 2008-2010 Town Car 2000-2005 Navigator 2007-2009 MKX MERCURY: 2008-2010 Grand Marquis, Mariner Hybrid, Mariner This article supersedes TSB 9-19-16 to update the Service Procedure. ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). ^ Avoid inhaling dust. ^ Avoid contact with eyes. ^ Store away from acids. ^ Wash thoroughly after handling. ^ Avoid release to the environment. NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Using compressed air (maximum inlet pressure) 100 PSI (689 kPa), clean the A/C ducts through the registers and blow off the evaporator core through the blower motor opening. NOTE THE ENTIRE EVAPORATOR CORE SURFACE MUST BE DRY FOR BEST RESULTS. NOTE WHILE PERFORMING THIS PROCEDURE AND SELECTING DIFFERENT VENT MODES SUCH AS FLOOR / PANEL AND FLOOR / DEFROST, IT MAY BE NECESSARY TO TEMPORARILY START THE ENGINE TO ENABLE MODE DOOR MOVEMENT. Clean A/C Ducts: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 5139 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel. 8. Turn on vacuum cleaner. 9. Working with one register at a time insert the vacuum line down each duct and blow shop air through each duct for 30 seconds. Be sure to close each register before moving on to the next register. 10. Change mode to floor I defrost. 11. Blow down each defroster duct for 30 seconds. 12. Alternate mode door between floor and floor / defrost three (3) times, giving the door time to move between each change. 13. Turn off vacuum cleaner. Clean Evaporator Core: 1. Change mode to full floor. 2. Ensure temperature is full cold. 3. Remove blower motor per Workshop Manual (WSM), Section 412. 4. Turn on vacuum cleaner. 5. Reach into blower opening with vacuum line and proceed to blow shop air for a minimum of 5 minutes, utilizing a very slow sweeping action. 6. Blow the entire core face with an up and down motion, then repeat moving from side to side. NOTE ATTENTION TO THE BLOW-OFF OF THE EVAPORATOR CORE SURFACE WILL DETERMINE EFFECTIVENESS OF REPAIR. 7. Install the blower motor per WSM, Section 412. 8. Open all registers. 9. Operate the A/C system in Max mode with the blower on the lowest setting. Monitor the temperature with a thermometer until the lowest temp is achieved. Switch to vent and monitor the temperature until ambient temperature is reached. 10. Repeat Step 9 three (3) additional times. 11. Switch the blower motor to high speed with the vent mode still selected. white flakes should not come out of the vents. If no white flakes are present continue to Step 12. 12. Disconnect vacuum cleaner and remove tape from floor duct. 13. Reassemble floor duct trim. 14. Blow powder off or vacuum dash board and vehicle interior as required. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 5140 OPERATION DESCRIPTION TIME 092106A 2004-2005 F-150, 1.2 Hrs. 2008-2010 Crown Victoria, Grand Marquis, Escape, Escape Hybrid, Mariner, Mariner Hybrid, 2005-2009 Focus, 2007-2009 Edge, MKX: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) 092106A 2000-2005 Expedition, 1.4 Hrs. Navigator, 2008-2010 Town Car, 2000-2003 F-150: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19860 49 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents Air Duct: All Technical Service Bulletins A/C - White Flakes Are Blowing From Dash Vents TSB 09-21-6 11/02/09 WHITE FLAKES COMING FROM A/C VENTS FORD: 2005-2009 Focus 2008-2010 Crown Victoria 2000-2005 Expedition, F-150 2007-2009 Edge 2008-2010 Escape Hybrid, Escape LINCOLN: 2008-2010 Town Car 2000-2005 Navigator 2007-2009 MKX MERCURY: 2008-2010 Grand Marquis, Mariner Hybrid, Mariner This article supersedes TSB 9-19-16 to update the Service Procedure. ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). ^ Avoid inhaling dust. ^ Avoid contact with eyes. ^ Store away from acids. ^ Wash thoroughly after handling. ^ Avoid release to the environment. NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Using compressed air (maximum inlet pressure) 100 PSI (689 kPa), clean the A/C ducts through the registers and blow off the evaporator core through the blower motor opening. NOTE THE ENTIRE EVAPORATOR CORE SURFACE MUST BE DRY FOR BEST RESULTS. NOTE WHILE PERFORMING THIS PROCEDURE AND SELECTING DIFFERENT VENT MODES SUCH AS FLOOR / PANEL AND FLOOR / DEFROST, IT MAY BE NECESSARY TO TEMPORARILY START THE ENGINE TO ENABLE MODE DOOR MOVEMENT. Clean A/C Ducts: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 5146 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel. 8. Turn on vacuum cleaner. 9. Working with one register at a time insert the vacuum line down each duct and blow shop air through each duct for 30 seconds. Be sure to close each register before moving on to the next register. 10. Change mode to floor I defrost. 11. Blow down each defroster duct for 30 seconds. 12. Alternate mode door between floor and floor / defrost three (3) times, giving the door time to move between each change. 13. Turn off vacuum cleaner. Clean Evaporator Core: 1. Change mode to full floor. 2. Ensure temperature is full cold. 3. Remove blower motor per Workshop Manual (WSM), Section 412. 4. Turn on vacuum cleaner. 5. Reach into blower opening with vacuum line and proceed to blow shop air for a minimum of 5 minutes, utilizing a very slow sweeping action. 6. Blow the entire core face with an up and down motion, then repeat moving from side to side. NOTE ATTENTION TO THE BLOW-OFF OF THE EVAPORATOR CORE SURFACE WILL DETERMINE EFFECTIVENESS OF REPAIR. 7. Install the blower motor per WSM, Section 412. 8. Open all registers. 9. Operate the A/C system in Max mode with the blower on the lowest setting. Monitor the temperature with a thermometer until the lowest temp is achieved. Switch to vent and monitor the temperature until ambient temperature is reached. 10. Repeat Step 9 three (3) additional times. 11. Switch the blower motor to high speed with the vent mode still selected. white flakes should not come out of the vents. If no white flakes are present continue to Step 12. 12. Disconnect vacuum cleaner and remove tape from floor duct. 13. Reassemble floor duct trim. 14. Blow powder off or vacuum dash board and vehicle interior as required. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 5147 OPERATION DESCRIPTION TIME 092106A 2004-2005 F-150, 1.2 Hrs. 2008-2010 Crown Victoria, Grand Marquis, Escape, Escape Hybrid, Mariner, Mariner Hybrid, 2005-2009 Focus, 2007-2009 Edge, MKX: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) 092106A 2000-2005 Expedition, 1.4 Hrs. Navigator, 2008-2010 Town Car, 2000-2003 F-150: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19860 49 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Removal and Replacement Air Duct: Removal and Replacement Footwell Duct - Rear Removal and Installation All vehicles 1. Remove the driver and front passenger seats. 2. Remove the floor console. 3. Remove the front door scuff plate trim panels and the lower A-pillar trim panels. Vehicles with automatic transmission 4. Detach the selector lever cable from the gearshift assembly. 1. Disconnect the selector lever cable end from the gearshift lever. 2. Remove the selector lever cable from the bracket. All vehicles Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Removal and Replacement > Page 5150 5. NOTE: Position the carpet to gain access to the floor ducts. Separate the wiring harness from the LH floor duct and position aside. 6. Remove the LH floor duct. 7. Remove the RH floor duct pin-type retainer. 8. Remove the RH floor duct. 9. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Removal and Replacement > Page 5151 Air Duct: Overhaul Instrument Panel Air Distribution Ducts Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Removal and Replacement > Page 5152 Disassembly and Assembly 1. Remove the passenger airbag module. For additional information, refer to Air Bag Systems. 2. Remove the Audio Control Module (ACM). 3. Remove the Instrument Cluster (IC). 4. Remove the instrument panel. 5. Remove the 4 defroster duct adapter screws and the defroster duct adapter. 6. Remove the 4 Front Display Interface Module (FDIM) screws and the FDIM. - Disconnect the FDIM electrical connector. 7. Remove the 2 instrument cluster opening instrument panel trim screws. 8. Remove the 4 instrument panel trim-to-audio unit bracket screws. 9. Remove the 2 instrument panel trim-to-audio unit bracket nuts. 10. Remove the 3 glove compartment screws and the glove compartment. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Removal and Replacement > Page 5153 11. Remove the 2 glove compartment latch striker screws and the glove compartment latch striker. 12. Remove the lower center instrument panel trim screw. 13. Remove the 4 lower steering column opening instrument panel trim screws. 14. Disconnect the headlamp switch and the message center switch electrical connectors. 15. Remove the 2 upper corner instrument panel trim screws. 16. Remove the 2 lower corner instrument panel trim screws. 17. Remove the 2 instrument panel support-to-defroster duct screws. 18. NOTE: The instrument panel trim will need to be positioned away from the instrument panel support to access the LH duct assembly upper center screw. Remove the 4 LH duct assembly screws and remove the LH duct assembly. 19. NOTE: The instrument panel trim will need to be positioned away from the instrument panel support to access the RH duct assembly upper center screw. Remove the 4 RH duct assembly screws and remove the RH duct assembly. 20. To assemble, reverse the assembly procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest for Air Register: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents Air Register: Customer Interest A/C - White Flakes Are Blowing From Dash Vents TSB 09-21-6 11/02/09 WHITE FLAKES COMING FROM A/C VENTS FORD: 2005-2009 Focus 2008-2010 Crown Victoria 2000-2005 Expedition, F-150 2007-2009 Edge 2008-2010 Escape Hybrid, Escape LINCOLN: 2008-2010 Town Car 2000-2005 Navigator 2007-2009 MKX MERCURY: 2008-2010 Grand Marquis, Mariner Hybrid, Mariner This article supersedes TSB 9-19-16 to update the Service Procedure. ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). ^ Avoid inhaling dust. ^ Avoid contact with eyes. ^ Store away from acids. ^ Wash thoroughly after handling. ^ Avoid release to the environment. NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Using compressed air (maximum inlet pressure) 100 PSI (689 kPa), clean the A/C ducts through the registers and blow off the evaporator core through the blower motor opening. NOTE THE ENTIRE EVAPORATOR CORE SURFACE MUST BE DRY FOR BEST RESULTS. NOTE WHILE PERFORMING THIS PROCEDURE AND SELECTING DIFFERENT VENT MODES SUCH AS FLOOR / PANEL AND FLOOR / DEFROST, IT MAY BE NECESSARY TO TEMPORARILY START THE ENGINE TO ENABLE MODE DOOR MOVEMENT. Clean A/C Ducts: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest for Air Register: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 5162 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel. 8. Turn on vacuum cleaner. 9. Working with one register at a time insert the vacuum line down each duct and blow shop air through each duct for 30 seconds. Be sure to close each register before moving on to the next register. 10. Change mode to floor I defrost. 11. Blow down each defroster duct for 30 seconds. 12. Alternate mode door between floor and floor / defrost three (3) times, giving the door time to move between each change. 13. Turn off vacuum cleaner. Clean Evaporator Core: 1. Change mode to full floor. 2. Ensure temperature is full cold. 3. Remove blower motor per Workshop Manual (WSM), Section 412. 4. Turn on vacuum cleaner. 5. Reach into blower opening with vacuum line and proceed to blow shop air for a minimum of 5 minutes, utilizing a very slow sweeping action. 6. Blow the entire core face with an up and down motion, then repeat moving from side to side. NOTE ATTENTION TO THE BLOW-OFF OF THE EVAPORATOR CORE SURFACE WILL DETERMINE EFFECTIVENESS OF REPAIR. 7. Install the blower motor per WSM, Section 412. 8. Open all registers. 9. Operate the A/C system in Max mode with the blower on the lowest setting. Monitor the temperature with a thermometer until the lowest temp is achieved. Switch to vent and monitor the temperature until ambient temperature is reached. 10. Repeat Step 9 three (3) additional times. 11. Switch the blower motor to high speed with the vent mode still selected. white flakes should not come out of the vents. If no white flakes are present continue to Step 12. 12. Disconnect vacuum cleaner and remove tape from floor duct. 13. Reassemble floor duct trim. 14. Blow powder off or vacuum dash board and vehicle interior as required. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest for Air Register: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 5163 OPERATION DESCRIPTION TIME 092106A 2004-2005 F-150, 1.2 Hrs. 2008-2010 Crown Victoria, Grand Marquis, Escape, Escape Hybrid, Mariner, Mariner Hybrid, 2005-2009 Focus, 2007-2009 Edge, MKX: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) 092106A 2000-2005 Expedition, 1.4 Hrs. Navigator, 2008-2010 Town Car, 2000-2003 F-150: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19860 49 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Register: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents Air Register: All Technical Service Bulletins A/C - White Flakes Are Blowing From Dash Vents TSB 09-21-6 11/02/09 WHITE FLAKES COMING FROM A/C VENTS FORD: 2005-2009 Focus 2008-2010 Crown Victoria 2000-2005 Expedition, F-150 2007-2009 Edge 2008-2010 Escape Hybrid, Escape LINCOLN: 2008-2010 Town Car 2000-2005 Navigator 2007-2009 MKX MERCURY: 2008-2010 Grand Marquis, Mariner Hybrid, Mariner This article supersedes TSB 9-19-16 to update the Service Procedure. ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). ^ Avoid inhaling dust. ^ Avoid contact with eyes. ^ Store away from acids. ^ Wash thoroughly after handling. ^ Avoid release to the environment. NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Using compressed air (maximum inlet pressure) 100 PSI (689 kPa), clean the A/C ducts through the registers and blow off the evaporator core through the blower motor opening. NOTE THE ENTIRE EVAPORATOR CORE SURFACE MUST BE DRY FOR BEST RESULTS. NOTE WHILE PERFORMING THIS PROCEDURE AND SELECTING DIFFERENT VENT MODES SUCH AS FLOOR / PANEL AND FLOOR / DEFROST, IT MAY BE NECESSARY TO TEMPORARILY START THE ENGINE TO ENABLE MODE DOOR MOVEMENT. Clean A/C Ducts: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Register: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 5169 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel. 8. Turn on vacuum cleaner. 9. Working with one register at a time insert the vacuum line down each duct and blow shop air through each duct for 30 seconds. Be sure to close each register before moving on to the next register. 10. Change mode to floor I defrost. 11. Blow down each defroster duct for 30 seconds. 12. Alternate mode door between floor and floor / defrost three (3) times, giving the door time to move between each change. 13. Turn off vacuum cleaner. Clean Evaporator Core: 1. Change mode to full floor. 2. Ensure temperature is full cold. 3. Remove blower motor per Workshop Manual (WSM), Section 412. 4. Turn on vacuum cleaner. 5. Reach into blower opening with vacuum line and proceed to blow shop air for a minimum of 5 minutes, utilizing a very slow sweeping action. 6. Blow the entire core face with an up and down motion, then repeat moving from side to side. NOTE ATTENTION TO THE BLOW-OFF OF THE EVAPORATOR CORE SURFACE WILL DETERMINE EFFECTIVENESS OF REPAIR. 7. Install the blower motor per WSM, Section 412. 8. Open all registers. 9. Operate the A/C system in Max mode with the blower on the lowest setting. Monitor the temperature with a thermometer until the lowest temp is achieved. Switch to vent and monitor the temperature until ambient temperature is reached. 10. Repeat Step 9 three (3) additional times. 11. Switch the blower motor to high speed with the vent mode still selected. white flakes should not come out of the vents. If no white flakes are present continue to Step 12. 12. Disconnect vacuum cleaner and remove tape from floor duct. 13. Reassemble floor duct trim. 14. Blow powder off or vacuum dash board and vehicle interior as required. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Register: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 5170 OPERATION DESCRIPTION TIME 092106A 2004-2005 F-150, 1.2 Hrs. 2008-2010 Crown Victoria, Grand Marquis, Escape, Escape Hybrid, Mariner, Mariner Hybrid, 2005-2009 Focus, 2007-2009 Edge, MKX: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) 092106A 2000-2005 Expedition, 1.4 Hrs. Navigator, 2008-2010 Town Car, 2000-2003 F-150: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19860 49 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Register - Passenger Side Air Register: Service and Repair Register - Passenger Side Register - Passenger Side Removal and Installation 1. NOTICE: Make sure that the tool is inserted behind the register housing, not the register trim ring. Prying on the register trim ring will damage the register assembly. Using a suitable tool, gently pry to disengage the register clips from the instrument panel while working around the perimeter of the register. 2. Remove the passenger side register. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Register - Passenger Side > Page 5173 Air Register: Service and Repair Register - Center Register - Center Removal and Installation 1. NOTE: The center registers are available only as part of the upper center instrument panel finish panel assembly. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Register - Passenger Side > Page 5174 Air Register: Service and Repair Register - Driver Side Register - Driver Side Removal and Installation 1. NOTICE: Make sure that the tool is inserted behind the register housing, not the register trim ring. Prying on the register trim ring will damage the register assembly. Using a suitable tool, gently pry to disengage the register clips from the instrument panel while working around the perimeter of the register. 2. Remove the driver side register. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5178 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5179 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection Climate Control System Component Tests Ambient Temperature Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Auxiliary Water Pump > Component Information > Locations > M/E Coolant Pump Motor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Auxiliary Water Pump > Component Information > Locations > M/E Coolant Pump Motor > Page 5184 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Auxiliary Water Pump > Component Information > Diagrams > Heater Pump Motor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Auxiliary Water Pump > Component Information > Diagrams > Heater Pump Motor > Page 5187 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Auxiliary Water Pump > Component Information > Diagrams > Page 5188 Auxiliary Water Pump: Description and Operation Heater Pump The heater pump is required to maintain engine coolant flow to the heater core for passenger compartment heating when the engine is not running. The PCM commands the heater pump on by energizing the heater pump control relay (HPCR). The pump is commanded on when the following conditions are met: - The key is in the ON/START position. - The engine coolant temperature is above a minimum threshold 0°C (32°F) nominal. - The inferred ambient temperature is below a calibrated value 32°C (90°F) nominal. - The engine speed is below a calibrated threshold (nominal 4,000 RPM) including engine OFF. - The climate control mode switch is in any position other than OFF. The pump is off when the climate control mode switch is set to OFF. Heater Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Auxiliary Water Pump > Component Information > Diagrams > Page 5189 Auxiliary Water Pump: Service and Repair Auxiliary Coolant Flow Pump Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the LH lower engine splash shield. 4. Release the clamp and disconnect the auxiliary coolant pump-to-thermostat hose. 5. Release the clamp and disconnect the heater outlet hose. 6. Disconnect the auxiliary coolant flow pump electrical connector. 7. Remove the 2 auxiliary coolant flow pump bolts. - To install, tighten to 4 Nm (35 lb-in). 8. Remove the auxiliary coolant flow pump and rubber bracket assembly. 9. NOTE: Lubricate the coolant hoses with plain water only if needed. Do not use soap or other detergents. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Auxiliary Water Pump > Component Information > Diagrams > Page 5190 - Fill the engine cooling system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Auxiliary Water Pump Relay > Component Information > Locations > M/E Coolant Pump Relay Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Auxiliary Water Pump Relay > Component Information > Locations > M/E Coolant Pump Relay > Page 5195 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5209 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5210 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5211 Blower Motor: 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5212 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5213 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5214 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5215 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5216 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5217 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5218 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5219 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5220 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5221 Blower Motor: Service and Repair Blower Motor Removal and Installation 1. Disconnect the blower motor electrical connector. 2. Release the 2 blower motor vent tube clips and pull the vent tube down until it is disengaged from the heater core and evaporator core housing. 3. NOTE: The carpet below the blower motor must be slightly repositioned to remove the blower motor. Rotate the blower motor counterclockwise to disengage it from the housing and remove the blower motor. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection Blower Motor Resistor: Testing and Inspection Climate Control System Component Tests Blower Motor Resistor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Page 5228 Blower Motor Resistor: Service and Repair Blower Motor Resistor Removal and Installation 1. Lower the glove compartment. 2. Disconnect the blower motor resistor electrical connector. 3. Remove the 2 blower motor resistor screws. - To install, tighten to 3 Nm (27 lb-in). 4. Remove the blower motor resistor. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 5232 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 5233 Blower Motor Switch: Service and Repair Blower Motor Speed Control Removal and Installation 1. Lower the glove compartment. 2. Disconnect the blower motor speed control electrical connector. 3. Remove the 2 blower motor speed control screws. - To install, tighten to 3 Nm (27 lb-in). 4. Remove the blower motor speed control. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations AIR DISTRIBUTION NOTE: A cabin air filter is available as a dealer-installed accessory. The accessory cabin air filter will be located in the air inlet under the right hand side of the cowl panel grill, if installed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations > Page 5237 Cabin Air Filter: Service and Repair AIR DISTRIBUTION NOTE: A cabin air filter is available as a dealer-installed accessory. The accessory cabin air filter will be located in the air inlet under the right hand side of the cowl panel grill, if installed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 5241 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 5242 Cabin Temperature Sensor / Switch: Testing and Inspection Climate Control System Component Tests In-Vehicle Temperature Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature and Humidity Sensor Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature and Humidity Sensor In-Vehicle Temperature and Humidity Sensor NOTE: In-vehicle temperature and humidity sensor shown. In-vehicle temperature sensor similar. Removal and Installation 1. NOTICE: Only position the instrument cluster finish panel away from the instrument panel enough to detach the in-vehicle temperature sensor without stressing the attached components. If the instrument cluster finish panel is positioned too far away from the instrument panel, damage to the wire harness or instrument cluster finish panel could result. Detach the instrument cluster finish panel and position it away from the instrument panel to allow access to the in-vehicle temperature sensor. 2. Release the 2 clips and detach the in-vehicle temperature sensor or in-vehicle temperature and humidity sensor. 3. Disconnect the in-vehicle temperature sensor or in-vehicle temperature and humidity sensor electrical connector. 4. Detach the aspirator hose from the venturi at the heater core and evaporator core housing. 5. Detach the aspirator hose from the instrument panel. 6. Remove the in-vehicle temperature sensor or in-vehicle temperature and humidity sensor. 7. NOTE: The venturi must be aligned correctly with the heater core and evaporator core housing for installation. When installing the venturi, it must be pressed into the heater core and evaporator core housing until an audible click is heard to indicated that it is correctly attached. Remove the venturi (if needed). 8. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature and Humidity Sensor > Page 5245 Cabin Temperature Sensor / Switch: Service and Repair Ambient Air Temperature Sensor Ambient Air Temperature Sensor Removal and Installation 1. Detach the ambient air temperature sensor electrical connector from the bumper. 2. Disconnect and remove the ambient air temperature sensor. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Air gap between pulley and clutch plate..................................................................................................................................0.35-0.75 mm (0.014-0.030 in) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5250 Compressor Clutch: Adjustments Air Conditioning (A/C) Clutch Air Gap Adjustment 1. Check the A/C clutch air gap at 3 equally spaced places between the clutch plate and the A/C clutch pulley. 2. If the A/C clutch air gap is out of range, remove the clutch plate. Add or remove spacers between the clutch plate hub and the compressor shaft until the clearance is within specification. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 5254 Compressor Clutch Coil: Service and Repair Clutch and Clutch Field Coil - Hybrid Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 5255 Removal 1. Remove the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor - Hybrid See: Service and Repair. 2. Remove the A/C clutch disc and hub nut. 1. Using the Compressor Clutch Holding Tool, hold the A/C clutch disc and hub. 2. Remove the A/C clutch disc and hub nut. 3. Remove the A/C clutch disc and hub. 4. Remove the A/C compressor pulley snap ring. 5. NOTICE: Do not use air tools. Damage to the Air Conditioning (A/C) clutch pulley or A/C compressor may result. Using the Compressor Pulley Remover, remove the A/C compressor pulley. 6. Remove the A/C clutch field coil snap ring. 7. Remove the A/C clutch field coil. 1. Remove the thermal protection switch bolt and bracket. 2. Detach the thermal protection switch from the A/C compressor. 8. Remove the A/C clutch field coil and thermal protection switch assembly. Installation NOTE: A new A/C compressor may come equipped with a clutch and pulley. If not, the A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and a new A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed. 1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage. - Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat. - Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 5256 - Inspect for roughness in the A/C compressor pulley bearing. 2. Clean the A/C clutch field coil and pulley mounting surfaces. 3. Apply a pea-sized drop of silicone sealant to the thermal protection switch socket in the A/C compressor housing. 4. Install the A/C clutch field coil. 1. Install the A/C clutch field coil. 2. Install the thermal protection switch and bracket. 3. Tighten the thermal protection switch bolt to 6 Nm (53 lb-in). 5. NOTE: The A/C compressor pulley is a tight fit on the A/C compressor. It must be correctly aligned during installation. Install the A/C compressor pulley. 1. Install the A/C Compressor Pulley Installer. 2. Install the A/C compressor pulley. 6. Install the A/C compressor pulley snap ring with the bevel side out. 7. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening. 8. Install the A/C clutch disc and hub. 9. Install the A/C compressor clutch disc and hub nut. 1. Hold the A/C clutch disc and hub with the Compressor Clutch Holding Tool. 2. Tighten the nut to 26 Nm (19 lb-ft). 10. Measure and adjust the clutch air gap by removing or adding A/C clutch disc and hub spacers. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 5257 11. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor - Hybrid See: Service and Repair. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5261 Compressor Clutch Relay: Description and Operation Air Conditioning (A/C) Clutch Relay The A/C clutch relay (may be referred to as the wide open throttle (WOT) A/C cutoff relay) is wired normally open. There is no direct electrical connection between the A/C switch or electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives a signal indicating that A/C is requested. When A/C is requested, the PCM checks other A/C related inputs that are available. If these inputs indicate A/C operation is OK, and the engine conditions are OK (coolant temperature, engine RPM, throttle position), the PCM grounds the wide open throttle A/C cut-off (WAC) output, closing the relay contacts and sending voltage to the A/C clutch. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation Condenser HVAC: Description and Operation Air Conditioning A/C Condenser The A/C condenser is an aluminum fin-and-micro-channel design heat exchanger located in front of the vehicle radiator. It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and by condensing gas to liquid refrigerant as it is cooled. On 2.5L or 3.0L (4V) vehicles equipped with an automatic transmission, the top portion of the condenser is partitioned from the refrigerant system and is used for transmission fluid cooling. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 5265 Condenser HVAC: Service and Repair Condenser Core - Hybrid Removal and Installation NOTE: If a condenser core leak is suspected, the condenser core must be leak tested before it is removed from the vehicle. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the motor electronics cooler. 4. Remove the 4 radiator bracket bolts. - To install, tighten to 8 Nm (71 lb-in). 5. Detach and remove the RH and LH radiator brackets. 6. Remove the condenser outlet and inlet fitting nuts and disconnect the fittings. - Discard the O-ring seals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 5266 - To install, tighten to 15 Nm (133 lb-in). 7. Remove the 2 condenser bolts. - To install, tighten to 7 Nm (62 lb-in). 8. Remove the condenser core. 9. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Heating Ventilation Air Conditioning (HVAC) Module Control Assembly: Service and Repair Heating Ventilation Air Conditioning (HVAC) Module Heating Ventilation Air Conditioning (HVAC) Module Removal and Installation NOTE: When installing a new HVAC module on vehicles equipped with Electronic Manual Temperature Control (EMTC), the Programmable Module Installation (PMI) procedure must be carried out to configure the new module to the vehicle. Refer to Information Bus. 1. Remove the middle center instrument panel finish panel. 2. Remove the 4 HVAC module screws. 3. Remove the HVAC module. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Heating Ventilation Air Conditioning (HVAC) Module > Page 5271 Control Assembly: Service and Repair Passenger Zone Valve Passenger Zone Valve Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Recover the refrigerant. 2. Disconnect the passenger zone valve electrical connector. 3. Disconnect the 2 passenger zone valve fittings. - Discard the O-ring seals. - To install, tighten to 17 Nm (150 lb-in). 4. Remove the passenger zone valve bracket nut. - To install, tighten to 7 Nm (62 lb-in). 5. Remove the passenger zone valve. 6. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 7. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 11-3-9 > Mar > 11 > A/C - Poor Cooling Performance Control Module HVAC: Customer Interest A/C - Poor Cooling Performance TSB 11-3-9 03/15/11 HYBRID - LACK OF A/C COOLING FORD: 2009 Escape MERCURY: 2009 Mariner ISSUE Some 2009 Escape and Mariner Hybrid vehicles equipped with electronic automatic temperature control (EATC) may exhibit a lack of A/C cooling. Low battery voltage during a previous vehicle start may cause the heating ventilation air conditioning (HVAC) module to function in conventional gasoline mode instead of hybrid vehicle mode. ACTION Follow Service Procedure to correct the condition. SERVICE PROCEDURE 1. To determine if the HVAC control module has defaulted to gasoline mode, first turn off the A/C and Recirculated Air buttons on the HVAC control head. 2. Turn off the HVAC control head. 3. Press the ECON button, the yellow led will light up. 4. Does the A/C and recirculated air buttons also light up when the ECON button is pressed? a. Yes - HVAC module is in gasoline mode, proceed to Step 5. b. No - HVAC module is not in gas mode, this procedure does not apply. 5. Reprogram the HVAC module to the latest calibration using IDS release 71.00 and higher. This new calibration is not included in the VCM 2010.11 DVD. Calibration files may also be obtained at the website. 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 110309A 2009 Escape and Mariner 0.3 Hr. Hybrid: Reprogram The HAVC Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19980 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11-3-9 > Mar > 11 > A/C - Poor Cooling Performance Control Module HVAC: All Technical Service Bulletins A/C - Poor Cooling Performance TSB 11-3-9 03/15/11 HYBRID - LACK OF A/C COOLING FORD: 2009 Escape MERCURY: 2009 Mariner ISSUE Some 2009 Escape and Mariner Hybrid vehicles equipped with electronic automatic temperature control (EATC) may exhibit a lack of A/C cooling. Low battery voltage during a previous vehicle start may cause the heating ventilation air conditioning (HVAC) module to function in conventional gasoline mode instead of hybrid vehicle mode. ACTION Follow Service Procedure to correct the condition. SERVICE PROCEDURE 1. To determine if the HVAC control module has defaulted to gasoline mode, first turn off the A/C and Recirculated Air buttons on the HVAC control head. 2. Turn off the HVAC control head. 3. Press the ECON button, the yellow led will light up. 4. Does the A/C and recirculated air buttons also light up when the ECON button is pressed? a. Yes - HVAC module is in gasoline mode, proceed to Step 5. b. No - HVAC module is not in gas mode, this procedure does not apply. 5. Reprogram the HVAC module to the latest calibration using IDS release 71.00 and higher. This new calibration is not included in the VCM 2010.11 DVD. Calibration files may also be obtained at the website. 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 110309A 2009 Escape and Mariner 0.3 Hr. Hybrid: Reprogram The HAVC Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19980 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 5285 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 5286 Control Module HVAC: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 5287 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation Coupler HVAC: Description and Operation Air Conditioning Refrigerant Line Fittings NOTICE: Use only a plastic or nonmetallic tool for removing O-ring seals and gasket seals from the refrigerant line fittings. Use of a metallic tool will create scratches on the sealing surface of the fitting that can result in refrigerant system leaks. Whenever a refrigerant line fitting is disconnected, the fitting must be cleaned of any foreign material and new O-ring seals and/or gasket seals must be installed. Use only the O-ring seals and gasket seals specified in the Ford Master Parts Catalog. If a refrigerant system line fitting must remain disconnected for an extended period of time, it should be capped to avoid contamination of the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Auxiliary Evaporation Outlet and Inlet-Front Evaporator Case: Service and Repair Auxiliary Evaporation Outlet and Inlet-Front Auxiliary Evaporator Outlet and Inlet Line - Front Material Front Connection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Auxiliary Evaporation Outlet and Inlet-Front > Page 5298 Intermediate Connection Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. See: Refrigerant 3. Remove the front auxiliary evaporator outlet line front fitting nut and disconnect the fitting. ^ Discard the 0-ring seal and gasket seal. ^ To install, tighten to 15 Nm (11 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Auxiliary Evaporation Outlet and Inlet-Front > Page 5299 4. Remove the front auxiliary evaporator inlet line front fitting nut and disconnect the fitting. ^ Discard the 0-ring seal. ^ To install, tighten to 8 Nm (71 lb-in). 5. Disconnect the 2 front auxiliary evaporator outlet and inlet line mid-joint fitting nuts and disconnect the fittings. ^ Discard the 0-ring seals. ^ To install, tighten to 8 Nm (71 lb-in) 6. Remove the front auxiliary evaporator outlet and inlet line bracket bolt. To install, tighten to 6 Nm (53 lb-in). 7. Remove the auxiliary line dash panel bracket nut and detach the bracket. To install, tighten to 6 Nm (53 lb-in). 8. NOTE: The auxiliary line bracket retainers are unscrewed for removal and pushed into place for installation. Remove the 2 auxiliary line bracket retainers and the front auxiliary evaporator outlet and inlet lines. 9. To install, reverse the removal procedure. ^ Install a new gasket seal and new 0-nag seals. ^ Lubricate the refrigerant system with the correct amount of clean PAG oil. See: Refrigerant 10. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Auxiliary Evaporation Outlet and Inlet-Front > Page 5300 Evaporator Case: Service and Repair Auxiliary Evaporation Outlet and Inlet-Rear Auxiliary Evaporator Outlet and Inlet Line - Rear Material Rear Connection NOTE: A/C service lines shown NOTE: This vehicle is not equipped with an in-line Thermostatic Expansion Valve (TXV) filter in the auxiliary evaporator inlet line fitting. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Auxiliary Evaporation Outlet and Inlet-Front > Page 5301 Intermediate Connection NOTE: A/C service lines Shown. Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. NOTE: The rear auxiliary evaporator outlet end inlet lines are installed from the factory as one-piece assemblies which must be cut for removal Replacement lines must be installed if the lines are cut The replacement parts are supplied as separate kits containing multiple piece lines for ease of installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. See: Refrigerant 3. Remove the 2 rear auxiliary evaporator outlet and inlet line rear fitting nuts and disconnect the fittings ^ Discard the 0-ring seals ^ To install, tighten to 8 Nm (71 lb-in) 4. Remove the rear auxiliary evaporator outlet and inlet line rear bracket bolt ^ To install tighten to 6 Nm (53 lb-in) 5. NOTE: If the vehicle is equipped with factory lines, it is necessary to cut the rear auxiliary evaporator outlet and inlet lines for removal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Auxiliary Evaporation Outlet and Inlet-Front > Page 5302 If equipped, disconnect the rear auxiliary evaporator outlet and inlet line tube-O fittings. ^ Discard the 0-ring seals ^ To install, tighten the 3/8-inch inlet line tube-0 fitting to 10 Nm (89 lb-in) ^ To install, tighten the 5/8-inch Outlet line tube-0 fitting to 37 Nm (27 lb-ft). 6. Remove the 2 front auxiliary evaporator outlet and inlet line mid-joint fitting nuts and disconnect the fittings. ^ Discard the 0-ring seals ^ To install, tighten to 8 Nm (71 lb-in 7. Remove the rear auxiliary evaporator outlet and inlet line front bracket bolt. ^ To install, tighten 6 Nm (53 lb-in). 8. NOTE The auxiliary line bracket retainers are unscrewed for removal and pushed into place for installation Remove the 2 rear auxiliary line bracket retainers and remove the lines. 9. To install, reverse the removal procedure ^ Install new 0-ring seals ^ Lubricate the refrigerant system with the correct amount of clean PAG oil. See: Refrigerant Oil 10. Evacuate, teak test and charge the refrigerant system. See: Refrigerant Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents Evaporator Core: Customer Interest A/C - White Flakes Are Blowing From Dash Vents TSB 09-21-6 11/02/09 WHITE FLAKES COMING FROM A/C VENTS FORD: 2005-2009 Focus 2008-2010 Crown Victoria 2000-2005 Expedition, F-150 2007-2009 Edge 2008-2010 Escape Hybrid, Escape LINCOLN: 2008-2010 Town Car 2000-2005 Navigator 2007-2009 MKX MERCURY: 2008-2010 Grand Marquis, Mariner Hybrid, Mariner This article supersedes TSB 9-19-16 to update the Service Procedure. ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). ^ Avoid inhaling dust. ^ Avoid contact with eyes. ^ Store away from acids. ^ Wash thoroughly after handling. ^ Avoid release to the environment. NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Using compressed air (maximum inlet pressure) 100 PSI (689 kPa), clean the A/C ducts through the registers and blow off the evaporator core through the blower motor opening. NOTE THE ENTIRE EVAPORATOR CORE SURFACE MUST BE DRY FOR BEST RESULTS. NOTE WHILE PERFORMING THIS PROCEDURE AND SELECTING DIFFERENT VENT MODES SUCH AS FLOOR / PANEL AND FLOOR / DEFROST, IT MAY BE NECESSARY TO TEMPORARILY START THE ENGINE TO ENABLE MODE DOOR MOVEMENT. Clean A/C Ducts: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 5311 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel. 8. Turn on vacuum cleaner. 9. Working with one register at a time insert the vacuum line down each duct and blow shop air through each duct for 30 seconds. Be sure to close each register before moving on to the next register. 10. Change mode to floor I defrost. 11. Blow down each defroster duct for 30 seconds. 12. Alternate mode door between floor and floor / defrost three (3) times, giving the door time to move between each change. 13. Turn off vacuum cleaner. Clean Evaporator Core: 1. Change mode to full floor. 2. Ensure temperature is full cold. 3. Remove blower motor per Workshop Manual (WSM), Section 412. 4. Turn on vacuum cleaner. 5. Reach into blower opening with vacuum line and proceed to blow shop air for a minimum of 5 minutes, utilizing a very slow sweeping action. 6. Blow the entire core face with an up and down motion, then repeat moving from side to side. NOTE ATTENTION TO THE BLOW-OFF OF THE EVAPORATOR CORE SURFACE WILL DETERMINE EFFECTIVENESS OF REPAIR. 7. Install the blower motor per WSM, Section 412. 8. Open all registers. 9. Operate the A/C system in Max mode with the blower on the lowest setting. Monitor the temperature with a thermometer until the lowest temp is achieved. Switch to vent and monitor the temperature until ambient temperature is reached. 10. Repeat Step 9 three (3) additional times. 11. Switch the blower motor to high speed with the vent mode still selected. white flakes should not come out of the vents. If no white flakes are present continue to Step 12. 12. Disconnect vacuum cleaner and remove tape from floor duct. 13. Reassemble floor duct trim. 14. Blow powder off or vacuum dash board and vehicle interior as required. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 5312 OPERATION DESCRIPTION TIME 092106A 2004-2005 F-150, 1.2 Hrs. 2008-2010 Crown Victoria, Grand Marquis, Escape, Escape Hybrid, Mariner, Mariner Hybrid, 2005-2009 Focus, 2007-2009 Edge, MKX: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) 092106A 2000-2005 Expedition, 1.4 Hrs. Navigator, 2008-2010 Town Car, 2000-2003 F-150: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19860 49 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents Evaporator Core: All Technical Service Bulletins A/C - White Flakes Are Blowing From Dash Vents TSB 09-21-6 11/02/09 WHITE FLAKES COMING FROM A/C VENTS FORD: 2005-2009 Focus 2008-2010 Crown Victoria 2000-2005 Expedition, F-150 2007-2009 Edge 2008-2010 Escape Hybrid, Escape LINCOLN: 2008-2010 Town Car 2000-2005 Navigator 2007-2009 MKX MERCURY: 2008-2010 Grand Marquis, Mariner Hybrid, Mariner This article supersedes TSB 9-19-16 to update the Service Procedure. ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). ^ Avoid inhaling dust. ^ Avoid contact with eyes. ^ Store away from acids. ^ Wash thoroughly after handling. ^ Avoid release to the environment. NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Using compressed air (maximum inlet pressure) 100 PSI (689 kPa), clean the A/C ducts through the registers and blow off the evaporator core through the blower motor opening. NOTE THE ENTIRE EVAPORATOR CORE SURFACE MUST BE DRY FOR BEST RESULTS. NOTE WHILE PERFORMING THIS PROCEDURE AND SELECTING DIFFERENT VENT MODES SUCH AS FLOOR / PANEL AND FLOOR / DEFROST, IT MAY BE NECESSARY TO TEMPORARILY START THE ENGINE TO ENABLE MODE DOOR MOVEMENT. Clean A/C Ducts: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 5318 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel. 8. Turn on vacuum cleaner. 9. Working with one register at a time insert the vacuum line down each duct and blow shop air through each duct for 30 seconds. Be sure to close each register before moving on to the next register. 10. Change mode to floor I defrost. 11. Blow down each defroster duct for 30 seconds. 12. Alternate mode door between floor and floor / defrost three (3) times, giving the door time to move between each change. 13. Turn off vacuum cleaner. Clean Evaporator Core: 1. Change mode to full floor. 2. Ensure temperature is full cold. 3. Remove blower motor per Workshop Manual (WSM), Section 412. 4. Turn on vacuum cleaner. 5. Reach into blower opening with vacuum line and proceed to blow shop air for a minimum of 5 minutes, utilizing a very slow sweeping action. 6. Blow the entire core face with an up and down motion, then repeat moving from side to side. NOTE ATTENTION TO THE BLOW-OFF OF THE EVAPORATOR CORE SURFACE WILL DETERMINE EFFECTIVENESS OF REPAIR. 7. Install the blower motor per WSM, Section 412. 8. Open all registers. 9. Operate the A/C system in Max mode with the blower on the lowest setting. Monitor the temperature with a thermometer until the lowest temp is achieved. Switch to vent and monitor the temperature until ambient temperature is reached. 10. Repeat Step 9 three (3) additional times. 11. Switch the blower motor to high speed with the vent mode still selected. white flakes should not come out of the vents. If no white flakes are present continue to Step 12. 12. Disconnect vacuum cleaner and remove tape from floor duct. 13. Reassemble floor duct trim. 14. Blow powder off or vacuum dash board and vehicle interior as required. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 5319 OPERATION DESCRIPTION TIME 092106A 2004-2005 F-150, 1.2 Hrs. 2008-2010 Crown Victoria, Grand Marquis, Escape, Escape Hybrid, Mariner, Mariner Hybrid, 2005-2009 Focus, 2007-2009 Edge, MKX: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) 092106A 2000-2005 Expedition, 1.4 Hrs. Navigator, 2008-2010 Town Car, 2000-2003 F-150: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19860 49 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5320 Evaporator Core: Description and Operation Air Conditioning Evaporator Core NOTE: A second (auxiliary) evaporator core is used for HVTB cooling on hybrid vehicles. The evaporator core is an aluminum plate/fin-type and is located in the heater core and evaporator core housing. A mixture of liquid refrigerant and oil enters the bottom of the evaporator core through the evaporator core inlet tube and continues out of the evaporator core through the evaporator core outlet tube as a vapor. During A/C compressor operation, airflow from the blower motor is cooled and dehumidified as it flows through the evaporator core fins. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5321 Evaporator Core: Testing and Inspection Climate Control System Component Tests Evaporator/Condenser Core - On-Vehicle Leak Test 1. Discharge and recover the refrigerant. Refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. 2. Disconnect the suspect evaporator core (leave the Thermostatic Expansion Valve (TXV) attached to the evaporator core) or condenser core from the A/C system. 3. Clean the fittings. 4. Connect the appropriate test fittings from the A/C Fittings Set to the condenser or evaporator core/TXV tube connections. 5. 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 that will activate the valve. The test is not valid if the shut-off valve does not open. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the evaporator core/TXV or condenser core. Connect the yellow hose to a known good vacuum pump. 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 evaporator core or 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 evaporator core or 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 evaporator core or 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 condenser core does leak, as verified by the above procedure, install a new condenser core. If the evaporator core/TXV does leak, as verified by the above procedure, disconnect the TXV and recheck the evaporator core for a leak. If the evaporator core does leak, install a new evaporator core or condenser core. TEST the system for normal operation. If the evaporator core does not leak, install new evaporator core/TXV seals and retest the evaporator core/TXV. If the evaporator core/TXV does leak, install a new TXV. TEST the system for normal operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5325 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Air Conditioning Evaporator Temperature Sensor / Switch: Description and Operation Air Conditioning Air Conditioning Evaporator Discharge Air Temperature Sensor NOTE: A second (auxiliary) evaporator discharge air temperature sensor is used for the auxiliary evaporator core on hybrid vehicles. The evaporator discharge air temperature sensor contains a thermistor. The resistance of this thermistor varies by a specific amount based on the evaporator discharge air temperature. The HVAC module measures a voltage ratio between the reference voltage it supplies to the sensor and the sensor return voltage to determine this resistance and the associated discharge air temperature. The evaporator discharge air temperature sensor maintains evaporator core temperature and prevents icing of the evaporator core. It does this by signaling the HVAC module to switch off the A/C request signal to the instrument cluster on 2.5L or 3.0L (4V) vehicles, or signaling the PCM to cycle the A/C compressor off when the evaporator discharge air temperature sensor reading falls below acceptable levels. The A/C request or A/C compressor will be switched back on when the evaporator temperature rises above acceptable levels. On hybrid vehicles, the A/C compressor will continue to run and the passenger zone valve will be closed by the PCM if the evaporator discharge air temperature sensor is reading a temperature below acceptable levels, but the TBCM is requesting A/C operation for HVTB cooling. This allows continued refrigerant flow to the auxiliary evaporator core while allowing the front (main) evaporator core to warm to acceptable levels. The evaporator discharge air temperature sensor is located on the heater core and evaporator core housing behind the glove compartment. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Air Conditioning > Page 5328 Evaporator Temperature Sensor / Switch: Description and Operation Engine Control Components Air Conditioning Evaporator Temperature (ACET) Sensor The ACET is connected to the dual automatic temperature control (DATC). Evaporator temperature is transmitted to the PCM from the DATC through the controller area network (CAN). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 5329 Evaporator Temperature Sensor / Switch: Service and Repair Air Conditioning (A/C) Evaporator Discharge Air Temperature Sensor Removal and Installation 1. Lower the glove compartment. 2. Detach the instrument panel wire harness pin-type retainer and position the wire harness away from the evaporator discharge air temperature sensor. 3. Disconnect the A/C evaporator discharge air temperature sensor electrical connector. 4. Gently pry upward and remove the A/C evaporator discharge air temperature sensor. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Thermostatic Expansion Valve (TXV) Expansion Block/Orifice Tube: Description and Operation Thermostatic Expansion Valve (TXV) Air Conditioning Thermostatic Expansion Valve (TXV) NOTE: A second (auxiliary) TXV is used for High Voltage Traction Battery (HVTB) cooling on hybrid vehicles. The TXV is located at the evaporator core inlet and outlet tubes at the dash panel at the rear of the engine compartment. The TXV provides a restriction to the flow of refrigerant from the high-pressure side of the refrigerant system and separates the low-pressure and high-pressure sides of the refrigerant system. Refrigerant entering and exiting the evaporator core passes through the TXV through 2 separate flow paths. An internal temperature sensing bulb senses the temperature of the refrigerant flowing out of the evaporator core and adjusts an internal pin-type valve to meter the refrigerant flow into the evaporator core. The internal pin-type valve decreases the amount of refrigerant entering the evaporator core at lower temperatures and increases the amount of refrigerant entering the evaporator core at higher temperatures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Thermostatic Expansion Valve (TXV) > Page 5334 Expansion Block/Orifice Tube: Description and Operation A/C Pressure Transducer Air Conditioning A/C Pressure Transducer (2.5L or 3.0L [4V] Only) The A/C pressure transducer monitors the compressor discharge pressure and communicates with the PCM. The PCM will interrupt A/C compressor operation in the event that the A/C pressure transducer indicates high system discharge pressures. It is also used to sense low charge conditions. If the pressure is below a predetermined value for a given ambient temperature, the PCM will not allow the clutch to engage. The A/C pressure transducer is located on the receiver/drier. It is not necessary to recover the refrigerant before removing the A/C pressure transducer. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Auxiliary Climate Control - Hybrid Expansion Block/Orifice Tube: Service and Repair Auxiliary Climate Control - Hybrid Thermostatic Expansion Valve Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. NOTE: The auxiliary Thermostatic Expansion Valve (TXV) is not interchangeable with the front (main) system TXV. 1. Remove the auxiliary climate control housing. For additional information, refer to Auxiliary Climate Control Housing See: Housing Assembly HVAC/Service and Repair/Auxiliary Climate Control Housing. 2. Remove the TXV-to-lower bracket nut and disconnect the lower TXV fittings. - Discard the O-ring seals. - To install, tighten to 11 Nm (97 lb-in). 3. NOTE: The upper TXV fitting is equipped with 2 O-ring seals not shown in graphic. Remove the 2 TXV-to-upper bracket bolts and remove the TXV. Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the TXV. 5. Remove the TXV stud. - To install, tighten to 11 Nm (97 lb-in). 6. To install, reverse the removal procedure. - Install new O-ring seals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Auxiliary Climate Control - Hybrid > Page 5337 Expansion Block/Orifice Tube: Service and Repair Climate Control Thermostatic Expansion Valve Removal and Installation 1. Recover the refrigerant. 2. Remove the Thermostatic Expansion Valve (TXV) fitting nut and disconnect the fitting. - Discard the gasket seals. - To install, tighten to 15 Nm (133 lb-in). 3. Remove the 2 TXV bolts and the TXV. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 4. To install, reverse the reverse the removal procedure. - If the TXV stud has become loose during removal, or has been removed for any reason, tighten the TXV stud to 6 Nm (53 lb-in) before the TXV fitting nut is reinstalled. - Install new O-ring seals and gasket seals. 5. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection > Heater Core Heater Core: Testing and Inspection Heater Core Climate Control System Component Tests Heater Core 1. NOTE: 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 as follows: Inspect for evidence of coolant leakage at the heater hose to heater core attachments. A coolant leak in the heater hose could follow the heater core tube to the heater core and appear as a leak in the heater core. 2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specified clamps can cause leakage at the heater hose connection and damage the heater core. Check the integrity of the heater hose clamps. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 5342 Heater Core: Testing and Inspection Heater Core - Plugged Climate Control System Component Tests Heater Core - Plugged 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, check the heater core inlet and outlet hoses to see if they are hot. 4. If the outlet only is not hot: - the heater core may have an air pocket. - the heater core may be plugged. 5. If the inlet only is not hot, the thermostat may not be working correctly. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 5343 Heater Core: Testing and Inspection Heater Core - Pressure Test Climate Control System Component Tests Heater Core - Pressure Test Use the Pressure Test Kit to carry out the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Drain the coolant from the cooling system. 2. Disconnect the heater hoses from the heater core. 3. Install a short piece of heater hose, approximately 101 mm (4 in) long on each heater core tube. 4. Fill the heater core and heater hoses with water and install plug BT-7422-B and adapter BT-7422-A from the Pressure Test Kit. Secure the heater hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Pressure Test Kit to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of 3 minutes. 8. If the pressure drops, check the heater hose connections to the core tubes for leaks. If the heater hoses do not leak, remove the heater core from the vehicle. 9. Carry out the Bench Test. See: Heater Core - Bench Test Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 5344 Heater Core: Testing and Inspection Heater Core - Bench Test Climate Control System Component Tests 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 in) test heater hoses with plug and adapter to the core tubes. Then connect the Pressure Test Kit to the adapter. 4. Apply 138 kPa (20 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection > Page 5345 Heater Core: Service and Repair Heater Core Removal and Installation NOTE: If a heater core leak is suspected, the heater core must be leak tested before the heater core is removed. NOTE: Use only the approved coolant for this vehicle. 1. Remove the heater core and evaporator core housing. For additional information, refer to Heater Core And Evaporator Core Housing See: Housing Assembly HVAC/Service and Repair/Heater Core And Evaporator Core Housing. 2. Remove the dash panel seal. 3. Remove the heater core bracket screw and the heater core bracket. - To install, tighten to 3 Nm (27 lb-in). 4. Remove the heater core. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation High Pressure Safety Valve HVAC: Description and Operation Air Conditioning Dual-Function Pressure Switch (Hybrid Only) The dual-function pressure switch is located on the receiver/drier and includes 2 separate sets of contacts that are opened at 2 different pressures. The first set of contacts in the dual-function pressure switch is used to interrupt A/C compressor operation in the event of excessively high discharge pressure in the high-pressure side of the refrigerant system. The PCM monitors the first set of contacts in the dual-function pressure switch in-series with the low-charge protection switch. When the contacts are open, the PCM will disengage the A/C compressor clutch. The second set of contacts in the dual-function pressure switch is used by the PCM to engage the high-speed cooling fan. When the A/C pressure rises above a preset level, the second set of contacts will close and the high-speed cooling fan will be engaged. The dual-function pressure switch is installed on a Schrader-type valve core fitting on the receiver/drier. It is not necessary to recover the refrigerant to remove the dual-function pressure switch. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Page 5349 High Pressure Safety Valve HVAC: Service and Repair Air Conditioning (A/C) Pressure Relief Valve - 2.5L, 3.0L (4V) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the A/C pressure relief valve and O-ring seal. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: A new O-ring seal will already be installed on the new A/C pressure relief valve service part. To install, reverse the removal procedure. - Add the correct amount of clean PAG refrigerant oil to the refrigerant system. 5. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly Hose/Line HVAC: Service and Repair Compressor Manifold and Tube Assembly Compressor Manifold and Tube Assembly - Hybrid Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the DC/DC converter. For additional information, refer to Hybrid Drive Systems. 4. Remove the front bumper cover. 5. Remove the condenser inlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 15 Nm (133 lb-in). 6. Remove the A/C compressor manifold bolt and disconnect the compressor manifold and tube from the A/C compressor. - Discard the O-ring seals. - To install, tighten to 20 Nm (177 lb-in). 7. Remove the 2 evaporator outlet line fitting nuts. - Discard the O-ring seals and gasket seals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5354 - To install, tighten to 15 Nm (133 lb-in). 8. Remove the compressor manifold and tube assembly bracket nut. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the compressor manifold and tube assembly. 10. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 11. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5355 Hose/Line HVAC: Service and Repair Compressor To Condenser Discharge Line Compressor to Condenser Discharge Line - 2.5L Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the RH lower engine splash shield. 4. Remove the front bumper cover. 5. Remove the condenser inlet fitting nut and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5356 6. Remove the A/C compressor suction fitting nut and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 7. Remove the A/C compressor discharge fitting nut and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 8. Remove the compressor-to-condenser discharge line. 9. To install, reverse the removal procedure. - Install new gasket and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5357 Hose/Line HVAC: Service and Repair Condenser To Receiver Drier Line Condenser to Receiver Drier Line Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Recover the refrigerant. 2. Remove the DC/DC converter. For additional information, refer to Hybrid Drive Systems. 3. Remove the front bumper cover. 4. Remove the compressor manifold and tube bracket nut. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5358 - To install, tighten to 8 Nm (71 lb-in). 5. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring seal. 6. Remove the evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 7. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 8. Remove the receiver/drier inlet fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 9. Remove the condenser-to-receiver/drier line. 10. To install, reverse the removal procedure. - Install new gasket seal and O-ring seal. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 11. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5359 Hose/Line HVAC: Service and Repair Evaporator Inlet Line Evaporator Inlet Line - Hybrid Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Recover the refrigerant. 2. Remove the evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 3. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5360 - To install, tighten to 15 Nm (133 lb-in). 4. Disconnect the low-charge protection switch electrical connector. 5. Remove the Thermostatic Expansion Valve (TXV) fitting nut and disconnect the fitting. - Discard the gasket seals. - To install, tighten to 15 Nm (133 lb-in). 6. Remove the passenger zone valve nut. - To install, tighten to 7 Nm (62 lb-in). 7. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 8. Remove the receiver/drier outlet fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 9. Disconnect the passenger zone valve electrical connector. 10. Detach the evaporator inlet line from the A/C line bracket. 11. Remove the evaporator inlet line. 12. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 13. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5361 Hose/Line HVAC: Service and Repair Compressor Manifold and Tube Assembly Compressor Manifold and Tube Assembly - Hybrid Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the DC/DC converter. For additional information, refer to Hybrid Drive Systems. 4. Remove the front bumper cover. 5. Remove the condenser inlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 15 Nm (133 lb-in). 6. Remove the A/C compressor manifold bolt and disconnect the compressor manifold and tube from the A/C compressor. - Discard the O-ring seals. - To install, tighten to 20 Nm (177 lb-in). 7. Remove the 2 evaporator outlet line fitting nuts. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5362 - Discard the O-ring seals and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 8. Remove the compressor manifold and tube assembly bracket nut. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the compressor manifold and tube assembly. 10. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 11. Evacuate, leak test and charge the refrigerant system. Compressor To Condenser Discharge Line Compressor to Condenser Discharge Line - 2.5L Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the RH lower engine splash shield. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5363 4. Remove the front bumper cover. 5. Remove the condenser inlet fitting nut and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 6. Remove the A/C compressor suction fitting nut and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 7. Remove the A/C compressor discharge fitting nut and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 8. Remove the compressor-to-condenser discharge line. 9. To install, reverse the removal procedure. - Install new gasket and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Condenser To Receiver Drier Line Condenser to Receiver Drier Line Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5364 Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Recover the refrigerant. 2. Remove the DC/DC converter. For additional information, refer to Hybrid Drive Systems. 3. Remove the front bumper cover. 4. Remove the compressor manifold and tube bracket nut. - To install, tighten to 8 Nm (71 lb-in). 5. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring seal. 6. Remove the evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 7. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5365 - To install, tighten to 15 Nm (133 lb-in). 8. Remove the receiver/drier inlet fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 9. Remove the condenser-to-receiver/drier line. 10. To install, reverse the removal procedure. - Install new gasket seal and O-ring seal. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 11. Evacuate, leak test and charge the refrigerant system. Evaporator Inlet Line Evaporator Inlet Line - Hybrid Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5366 Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Recover the refrigerant. 2. Remove the evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 3. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 4. Disconnect the low-charge protection switch electrical connector. 5. Remove the Thermostatic Expansion Valve (TXV) fitting nut and disconnect the fitting. - Discard the gasket seals. - To install, tighten to 15 Nm (133 lb-in). 6. Remove the passenger zone valve nut. - To install, tighten to 7 Nm (62 lb-in). 7. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 8. Remove the receiver/drier outlet fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 9. Disconnect the passenger zone valve electrical connector. 10. Detach the evaporator inlet line from the A/C line bracket. 11. Remove the evaporator inlet line. 12. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 13. Evacuate, leak test and charge the refrigerant system. Auxiliary Evaporator Outlet and Inlet Line - Front Auxiliary Evaporator Outlet and Inlet Line - Front Front Connection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5367 Intermediate Connection NOTE: A/C service lines shown. Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5368 3. Remove the front auxiliary evaporator outlet line front fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 4. Remove the front auxiliary evaporator inlet line front fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 5. Disconnect the 2 front auxiliary evaporator outlet and inlet line mid-joint fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 6. Remove the front auxiliary evaporator outlet and inlet line bracket bolt. - To install, tighten to 6 Nm (53 lb-in). 7. Remove the auxiliary line dash panel bracket nut and detach the bracket. - To install, tighten to 6 Nm (53 lb-in). 8. NOTE: The auxiliary line bracket retainers are unscrewed for removal and pushed into place for installation. Remove the 2 auxiliary line bracket retainers and the front auxiliary evaporator outlet and inlet lines. 9. To install, reverse the removal procedure. - Install a new gasket seal and new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Auxiliary Evaporator Outlet and Inlet Line - Rear Auxiliary Evaporator Outlet and Inlet Line - Rear Rear Connection NOTE: A/C service lines shown. NOTE: This vehicle is not equipped with an in-line Thermostatic Expansion Valve (TXV) filter in the auxiliary evaporator inlet line fitting. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5369 Intermediate Connection NOTE: A/C service lines shown. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5370 Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. NOTE: The rear auxiliary evaporator outlet and inlet lines are installed from the factory as one-piece assemblies which must be cut for removal. Replacement lines must be installed if the lines are cut. The replacement parts are supplied as separate kits containing multiple piece lines for ease of installation. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the 2 rear auxiliary evaporator outlet and inlet line rear fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the rear auxiliary evaporator outlet and inlet line rear bracket bolt. - To install, tighten to 6 Nm (53 lb-in). 5. NOTE: If the vehicle is equipped with factory lines, it is necessary to cut the rear auxiliary evaporator outlet and inlet lines for removal. If equipped, disconnect the rear auxiliary evaporator outlet and inlet line tube-O fittings. - Discard the O-ring seals. - To install, tighten the 3/8-inch inlet line tube-O fitting to 10 Nm (89 lb-in). - To install, tighten the 5/8-inch outlet line tube-O fitting to 37 Nm (27 lb-ft). 6. Remove the 2 front auxiliary evaporator outlet and inlet line mid-joint fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the rear auxiliary evaporator outlet and inlet line front bracket bolt. - To install, tighten to 6 Nm (53 lb-in). 8. NOTE: The auxiliary line bracket retainers are unscrewed for removal and pushed into place for installation. Remove the 2 rear auxiliary line bracket retainers and remove the lines. 9. To install, reverse the removal procedure. - Install new O-ring seals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5371 - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Evaporator Outlet Line Evaporator Outlet Line - Hybrid Removal and Installation 1. Recover the refrigerant. 2. Disconnect the low-charge protection switch electrical connector. 3. Remove the evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 4. Remove the Thermostatic Expansion Valve (TXV) fitting nut and disconnect the fitting. - Discard the gasket seals. - To install, tighten to 15 Nm (133 lb-in). 5. Detach the evaporator outlet line from the A/C line bracket. 6. Remove the evaporator outlet line. 7. To install, reverse the removal procedure. - Install a new O-ring and new gasket seals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 5372 - Lubricate the refrigerant system with the correct amount of clean PAG oil. 8. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Auxiliary Climate Control Housing Housing Assembly HVAC: Service and Repair Auxiliary Climate Control Housing Auxiliary Climate Control Housing Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the 2 auxiliary evaporator outlet and inlet line rear fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Auxiliary Climate Control Housing > Page 5377 4. Remove the 2 auxiliary line floorpan bracket nuts. - To install, tighten to 6 Nm (53 lb-in). 5. NOTE: The D-pillar bracket will remain in place. Remove the LH D-pillar trim panel. 6. NOTE: When installing, tighten the screws on the High Voltage Traction Battery (HVTB) first to make sure the duct is sealed correctly. Remove the 4 battery airflow duct screws, the 1 pin-type retainer and the battery airflow duct assembly. - To install, tighten to 2 Nm (18 lb-in). 7. Remove the 2 auxiliary climate control fresh air inlet duct nuts. - To install, tighten to 7 Nm (62 lb-in). 8. Remove the 2 auxiliary climate control housing bolts. - To install, tighten to 7 Nm (62 lb-in). 9. Disconnect the 2 auxiliary harness electrical connectors. 10. Disconnect the auxiliary evaporator discharge air temperature sensor electrical connector. 11. Remove the auxiliary climate control housing. 12. NOTE: The auxiliary climate control housing must be installed behind the lower portion of the D-pillar bracket. When installed correctly, the auxiliary climate control housing bolt will go through the D-pillar bracket first, then through the housing mounting location. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 13. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Auxiliary Climate Control Housing > Page 5378 Housing Assembly HVAC: Service and Repair Heater Core And Evaporator Core Housing Removal and Installation Heater Core And Evaporator Core Housing Removal and Installation NOTE: If a heater core leak is suspected, the heater core must be leak tested before the heater core is removed. 1. Drain the engine coolant. 2. Recover the refrigerant. 3. Remove the instrument panel. 4. Remove the Thermostatic Expansion Valve (TXV) fitting nut and disconnect the fitting. - Discard the gasket seals. - To install, tighten to 15 Nm (133 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Auxiliary Climate Control Housing > Page 5379 5. Release the clamps and disconnect the heater inlet and outlet hoses from the heater core. 6. Remove the 6 heater core and evaporator core housing nuts. - To install, tighten to 9 Nm (80 lb-in). 7. Remove the heater core and evaporator core housing in the following sequence. 1. Detach the heater core and evaporator core housing from the dash panel studs. 2. Rotate the RH side of the heater core and evaporator core housing toward the rear of the vehicle while pulling the housing toward the RH door opening to detach it from the rear footwell duct. 3. Remove the heater core and evaporator core housing. 8. Disassemble the heater core and evaporator core housing as needed. 9. To install, reverse the removal procedure. - Install new gasket seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Fill and bleed the engine cooling system. 11. Evacuate, leak test and charge the refrigerant system. Disassembly and Assembly Heater Core And Evaporator Core Housing Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Auxiliary Climate Control Housing > Page 5380 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Auxiliary Climate Control Housing > Page 5381 Disassembly and Assembly Plenum chamber 1. Remove the 2 RH temperature blend door actuator screws. - To install, tighten to 3 Nm (27 lb-in). 2. Detach the heater core and evaporator core housing wire harness from the plenum chamber. 3. Remove the 2 defrost/panel/floor mode door actuator screws. - To install, tighten to 3 Nm (27 lb-in). 4. Remove the defrost/panel/floor mode door actuator. 5. Remove the 6 plenum chamber screws. - To install, tighten to 3 Nm (27 lb-in). 6. Remove the plenum chamber. Air inlet duct 7. Detach the heater core and evaporator core housing wire harness from the air inlet duct. 8. Remove the 2 air inlet mode door actuator screws. - To install, tighten to 3 Nm (27 lb-in). 9. Remove the air inlet mode door actuator. Complete disassembly 10. Detach and remove the heater core and evaporator core housing wire harness. 11. Remove the 2 blower motor speed control or blower motor resistor screws. - To install, tighten to 3 Nm (27 lb-in). 12. Remove the blower motor speed control or blower motor resistor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Auxiliary Climate Control Housing > Page 5382 13. Remove the heater core tube dash panel seal. 14. Remove the heater core bracket screw and the heater core bracket. - To install, tighten to 3 Nm (27 lb-in). 15. Remove the heater core. 16. Remove the Thermostatic Expansion Valve (TXV) dash panel seal. 17. Remove the heater core and evaporator core housing drain dash panel seal. 18. Remove the 2 LH temperature blend door actuator screws (if equipped). 19. Remove the LH temperature blend door actuator (if equipped). 20. Detach the 2 blower motor vent tube clips and disengage the vent tube from the heater core and evaporator core housing. 21. Rotate counterclockwise and remove the blower motor. 22. To assemble, reverse the disassembly procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Humidity Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Humidity Sensor > Component Information > Locations > Page 5386 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation Receiver Dryer: Description and Operation Air Conditioning Receiver/Drier NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. Damage to the receiver/drier includes leaks, physical damage to the receiver/drier shell or desiccant, or moisture contamination. Moisture contamination results only from a complete loss of refrigerant, and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than one hour. If even a slight amount of positive refrigerant pressure is present in the refrigerant system before repairs are carried out, a new receiver/drier should not be installed. The receiver/drier is mounted to the right of the radiator support for 2.5L or 3.0L (4V) vehicles, or at the RH shock tower for hybrid vehicles. It stores high-pressure liquid after it leaves the condenser core. A desiccant cartridge mounted inside the receiver/drier removes any retained moisture from the refrigerant. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 5390 Receiver Dryer: Service and Repair Receiver Drier - Hybrid Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. Damage to the receiver/drier includes leaks, physical damage to the receiver/drier shell or desiccant, or moisture contamination. Moisture contamination results only from a complete loss of refrigerant, and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than one hour. If even a slight amount of positive refrigerant pressure is present in the refrigerant system before repairs are carried out, a new receiver/drier should not be installed. NOTE: The receiver/drier fitting studs can be removed and installed separately from the receiver/drier and are available as service parts. If only the fitting studs are damaged, it is not necessary to install a new receiver/drier. 1. Recover the refrigerant. 2. Remove the evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 5391 3. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 4. Remove the passenger zone valve bracket nut. - To install, tighten to 7 Nm (62 lb-in). 5. Disconnect the dual-function pressure switch electrical connector and detach the wire harness from the receiver/drier bracket stud. 6. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the receiver/drier inlet and outlet fitting nuts and disconnect the outlet fitting. - Discard the outlet fitting O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 8. Remove the 2 receiver/drier nuts and disconnect the receiver/drier inlet fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 7 Nm (62 lb-in). 9. Remove the receiver/drier. 10. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 11. Evacuate, leak test and charge the refrigerant system. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Item..............................................................................................................................R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification........................................... ......................................................................................................................................................WS H-M17B19-A Fill Capacity.................................................................................................................... ...................................................................1.08 kg (38 oz) (2.38 lb) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5396 Refrigerant: Fluid Type Specifications Item..............................................................................................................................R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification........................................... ......................................................................................................................................................WS H-M17B19-A Fill Capacity.................................................................................................................... ...................................................................1.08 kg (38 oz) (2.38 lb) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 5397 Refrigerant: Testing and Inspection Refrigerant Identification Testing Refrigerant Identification 1. NOTE: A Refrigerant Blend Identifier with Printer must be used to identify gas samples taken directly from the refrigeration system or storage containers prior to recovering or charging the refrigerant system. Follow the instructions included with the Refrigerant Blend Identifier with Printer to obtain the sample for testing. 2. The Refrigerant Blend Identifier with Printer will display one of the following: - If the purity level of R-134a is 98% or greater by weight, the green PASS LED will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons and air will be displayed on the digital display. - If refrigerant R-134a does not meet the 98% purity level, the red FAIL LED will light and an alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22 and hydrocarbons will be displayed on the digital display. - If hydrocarbon concentrations are 2% or greater by weight, the red FAIL LED will light, "Hydrocarbon High" will be displayed on the digital display, and an alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22 and hydrocarbons will also be displayed on the digital display. 3. The percentage of air contained in the sample will be displayed if the R-134a content is 98% or greater. The Refrigerant Blend Identifier with Printer eliminates the effect of air when determining the refrigerant sample content because air is not considered a contaminant, although air can affect A/C system performance. When the Refrigerant Blend Identifier with Printer has determined that a refrigerant source is pure (R-134a is 98% or greater by weight) and air concentration levels are 2% or greater by weight, it will prompt the user if an air purge is desired. 4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the refrigerant is indeed contaminated. Contaminated Refrigerant Handling NOTICE: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a recovery/recycling equipment. Recovery of contaminated refrigerant will contaminate the recovered refrigerant supply and may damage the recovery/recycling equipment. NOTE: A new suction accumulator or receiver/drier must be installed as directed by the A/C system flushing procedure. 1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant only. - If this equipment is not available, contact an A/C service facility in the area with the correct equipment to carry out this service. 2. Determine and correct the cause of the customers initial concern. 3. Flush the A/C system. 4. Dispose of the contaminated refrigerant in accordance with all federal, state and local regulations. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging Refrigerant: Service and Repair Air Conditioning (A/C) System Recovery, Evacuation and Charging Air Conditioning (A/C) System Recovery, Evacuation and Charging Refrigerant System Recovery NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If the vehicle's A/C refrigerant is contaminated, refer the customer to the service Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 5400 facility that carried out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment manufacturer procedures and instructions. NOTE: Ford Motor Company recommends the use of R-134a refrigerant management equipment that meets the requirements of the SAE J2788 standard. NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out recovery. If a R-134a Refrigerant Management Machine is not available, refrigerant system recovery may be accomplished using a separate recovery station. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Prior to recovering, the purity of the refrigerant must be verified. For additional information, refer to Refrigerant Identification Testing . 2. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. Note the amount of oil removed during the refrigerant recovery (if any). Add that same amount back into the system once repairs are complete. 4. Once the R-134a Refrigerant Management Machine has recovered the refrigerant, switch OFF the power supply. 5. Allow the system to set for about 2 minutes, and observe the system vacuum reading. If the vacuum is not lost, disconnect the recovery equipment. 6. If the system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable for 2 minutes. 7. Carry out the required repairs. Refrigerant System Evacuation Using a R-134a Refrigerant Management Machine NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out recovery, evacuation and charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, evacuation may be accomplished using a separate Vacuum Pump and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of 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. 3. Turn OFF the Vacuum Pump. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Evacuation Using a R-134a Manifold Gauge Set and Vacuum Pump NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out evacuation of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, refrigerant system evacuation may be accomplished using a separate Vacuum Pump and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Connect the R-134a Manifold Gauge Set to the low-side and high-side service gauge port valves. 2. Connect the center (yellow) hose from the R-134a Manifold Gauge Set to the suction port on the Vacuum Pump. 3. Open all valves on the R-134a Manifold Gauge Set and both service gauge port valves. 4. Turn on the Vacuum Pump and evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 5401 101.1 kPa (30 in-Hg) as possible. Continue to operate the Vacuum Pump for a minimum of 45 minutes. 5. Close the high-side and low-side valves on the R-134a Manifold Gauge Set (not the service gauge port valves) and turn OFF the Vacuum Pump. 6. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Charging Using a R-134a Refrigerant Management Machine NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, refrigerant system charging may be accomplished using a separate Automatic Refrigerant Charging Meter and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Refrigerant Oil Adding See: Service and Repair/Refrigerant Oil Adding. 2. Connect a R-134a Refrigerant Management Machine to the low-side and high-side service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions provided by the equipment manufacturer. Refrigerant System Charging Using a R-134a Manifold Gauge Set and Automatic Refrigerant Charging Meter NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, refrigerant system charging may be accomplished using a separate Automatic Refrigerant Charging Meter and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Refrigerant Oil Adding See: Service and Repair/Refrigerant Oil Adding. 2. Assemble the R-134a Manifold Gauge Set, Automatic Refrigerant Charging Meter and R-134a supply tank following the Automatic Refrigerant Charging Meter operating instructions. 3. Charge the refrigerant system following the Automatic Refrigerant Charging Meter operating instructions. 4. If the refrigerant flow stops before the refrigerant charge is complete, start the engine, select MAX A/C operation and allow the refrigerant charge to complete. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 5402 Refrigerant: Service and Repair Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation WARNING: Use extreme care and observe all safety and service precautions related to the use of refrigerants as outlined on refrigerant tank and on recovery and charging equipment. Failure to follow these instructions may result in serious personal injury. NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If the vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment manufacturer's procedures and instructions. NOTICE: On vehicles being serviced for an internal compressor or desiccant failure, a new suction accumulator or receiver/drier, Thermostatic Expansion Valve (TXV) or evaporator core orifice and any hoses containing mufflers must be installed prior to filtering the Air Conditioning (A/C) system. Internal plumbing of these devices makes it impossible to correctly remove any foreign material. These components are typically discarded after A/C system contamination. Hoses without mufflers can normally be reused unless they are clogged with foreign material. The filter is intended for use on one vehicle only. 1. Orient the filter inlet toward the A/C condenser core. 2. NOTICE: The flexible extension adapters included in the A/C Flush Adapter Kit are designed for low-pressure flushing and are not designed for use with a charged refrigerant system. Do not make the condenser fitting connections using the flexible extension adapters or damage to the adapters and loss of refrigerant will occur. NOTE: The F8VZ-19E773-AB pancake filter is not permanently installed and will be removed at the end of this procedure. Disconnect the condenser outlet fitting and temporarily install the pancake filter between the 2 halves of the fitting. - Use flexible refrigerant hose of 17,238 kPa (2,500 psi) burst rating. - Make the connections using the correct adapters from the A/C Flush Adapter Kit and/or A/C Flush and Purge Fitting Kit. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 5403 3. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Refrigerant Oil Adding See: Service and Repair/Refrigerant Oil Adding. 4. Evacuate and charge the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. 5. Check all refrigerant system hoses, lines and the position of the newly installed filters to be sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 6. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Select A/C operation and set the blower motor speed to maximum. Start the engine and let it idle briefly. Make sure the A/C system is operating correctly. 7. Gradually bring the engine up to 1,200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1,000 rpm). Set the engine at 1,200 rpm and run it for one hour with the A/C system operating. 8. Stop the engine. 9. Recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. 10. Remove the adapters, flexible hoses and pancake filter from between the condenser and the condenser to evaporator tube. 11. Discard the pancake filter. It can be used one time only. 12. Reconnect the condenser outlet fitting. 13. Evacuate, charge and leak-test the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Control Solenoid Valve > Component Information > Diagrams > Battery Zone Valve Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Control Solenoid Valve > Component Information > Diagrams > Battery Zone Valve > Page 5408 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Control Solenoid Valve > Component Information > Diagrams > Page 5409 Refrigerant Control Solenoid Valve: Description and Operation Air Conditioning Refrigerant Distribution Valve (ACRDV) The ACRDV is a PCM-controlled solenoid that provides a regulated control of refrigerant flow to the passenger compartment loop. The PCM opens or closes the ACRDV based on the passenger compartment A/C request. The ACRDV is a normally closed valve, preventing the refrigerant flow. When the passenger compartment A/C is requested ON, the PCM provides a ground path to the solenoid which opens the ACRDV. Air Conditioning (A/C) Refrigerant Distribution Valve (ACRDV) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Control Solenoid Valve > Component Information > Diagrams > Page 5410 Refrigerant Control Solenoid Valve: Service and Repair Battery Zone Valve Removal and Installation NOTE: The battery zone valve is not interchangeable with the passenger zone valve. 1. Remove the auxiliary climate control housing. For additional information, refer to Auxiliary Climate Control Housing See: Housing Assembly HVAC/Service and Repair/Auxiliary Climate Control Housing. 2. Remove the 2 battery zone valve screws. - To install, tighten to 2 Nm (18 lb-in). 3. Loosen the nuts and disconnect the battery zone valve tube-O fittings. - Discard the O-ring seals. - To install, tighten to 17 Nm (150 lb-in). 4. Disconnect the electrical connector and remove the battery zone valve. 5. To install, reverse the removal procedure. - Install new O-ring seals. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Item.........................................................................................................................................PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D Specification............................................... ..................................................................................................................................................WSHM1C231-B Fill Capacity........................................................................................................................ ....................................325 ml (11 fl oz) See: Service and Repair Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5415 Refrigerant Oil: Fluid Type Specifications Item.........................................................................................................................................PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D Specification............................................... ..................................................................................................................................................WSHM1C231-B Fill Capacity........................................................................................................................ ....................................325 ml (11 fl oz) See: Service and Repair Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5416 Refrigerant Oil: Service and Repair Refrigerant Oil Adding Refrigerant Oil Adding NOTE: 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, some of the PAG 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. Refer to the chart below for refrigerant oil adding amounts and methods of installation. a If an excessive amount of PAG oil is lost due to a hose rupture/separation or other damage, the total system PAG oil capacity must be added. b The amount specified may be used for one or multiple O-ring leak repairs. Do not multiply the PAG oil amount by the number of O-ring leaks being repaired. Adding Refrigerant Oil After A/C Compressor Replacement Service A/C compressors shipped without clutch and pulley 1. Rotate the A/C compressor shaft 6 to 8 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 oz), pour the same amount plus 30 ml (1 oz) of clean PAG Refrigerant Compressor Oil (R-134a Systems) (YN-12-D) WSH M1C231-B or equivalent into the new A/C compressor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5417 - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 oz), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent 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 oz), pour 85 ml (3 oz) of clean A/C Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. Service A/C compressors shipped with clutch and pulley 2. Rotate the old A/C compressor shaft 6 to 8 revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is less than 89 ml (3 oz), remove 118 ml (4 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is 89 ml (3 oz), remove 89 ml (3 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is 118 ml (4 oz), remove 59 ml (2 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is 148 ml (5 oz), remove 29 ml (1 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is greater than 148 ml (5 oz), remove 0 ml (0 oz) from the new A/C compressor. Adding Refrigerant Oil After New Suction Accumulator or Receiver/Drier Replacement NOTE: This refrigerant oil adding method is to be used when a new suction accumulator or receiver drier only has been installed. If a new A/C compressor and evaporator core orifice or TXV have also been installed due to system contamination, refer to the appropriate heading. 1. Drill one 12.7 mm (1/2 in) hole in the old suction accumulator or receiver/drier cylinder and drain the oil into a clean measuring cup. 2. Add the same quantity of new PAG oil, plus the amount collected during refrigerant recovery and 60 ml (2 fl oz). Adding Refrigerant Oil After Multiple Component Replacement After A/C System Contamination NOTE: This refrigerant oil adding method is to be used when a new A/C compressor, suction accumulator or receiver drier and evaporator core orifice or TXV have been installed due to system contamination and the A/C system has been flushed. NOTE: Service A/C compressors are shipped without refrigerant oil. 1. Add 60 ml (2 fl oz) directly to the new A/C compressor suction port. 2. Inject the total vehicle PAG oil capacity minus 60 ml (2 fl oz) to the low-side service port during system charging. For the total PAG oil capacity specification, refer to the Specifications table. Oil Injection Using a Dye/Lubricant Injector NOTE: If fluorescent leak detection dye is also to be added during A/C charging, the dye may be added to the dye/lubricant injector, from the R-134a Loop/Add On Injector Kit-Set, along with the PAG oil. 1. Evacuate the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. 2. Assemble the dye/lubricant injector and the correct adapters from the R-134a Loop/Add On Injector Kit-Set to match the amount of refrigerant compressor oil to be injected. 3. Verify that all the valves on the dye/lubricant injector are closed. 4. Fill the dye/lubricant injector with the correct amount of clean, new PAG oil. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5418 5. Install the dye/lubricant injector between the low-side service gauge port valve and the refrigerant service station or manifold gauge set. 6. Open all valves and charge the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation High Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) High Pressure Switch The A/C high pressure switch is used for additional A/C system pressure control. For refrigerant containment control, the normally closed high pressure contacts open at a predetermined A/C pressure. This results in the A/C turning off, preventing the A/C pressure from rising to a level that would open the A/C high pressure relief valve. For fan control, the normally open medium pressure contacts close at a predetermined A/C pressure. This grounds the ACPSW circuit input to the PCM. The PCM then turns on the high speed fan to help reduce the pressure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Description and Operation Low Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Low Pressure Switch The A/C low pressure switch is used for additional A/C system pressure control. This normally closed switch opens when the refrigerant pressure drops below 152 kPa (22 psi). This results in the A/C turning off, preventing the evaporator from freezing. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Auxiliary Water Pump Relay > Component Information > Locations > M/E Coolant Pump Relay Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Auxiliary Water Pump Relay > Component Information > Locations > M/E Coolant Pump Relay > Page 5431 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5438 Compressor Clutch Relay: Description and Operation Air Conditioning (A/C) Clutch Relay The A/C clutch relay (may be referred to as the wide open throttle (WOT) A/C cutoff relay) is wired normally open. There is no direct electrical connection between the A/C switch or electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives a signal indicating that A/C is requested. When A/C is requested, the PCM checks other A/C related inputs that are available. If these inputs indicate A/C operation is OK, and the engine conditions are OK (coolant temperature, engine RPM, throttle position), the PCM grounds the wide open throttle A/C cut-off (WAC) output, closing the relay contacts and sending voltage to the A/C clutch. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 11-3-9 > Mar > 11 > A/C - Poor Cooling Performance Control Module HVAC: Customer Interest A/C - Poor Cooling Performance TSB 11-3-9 03/15/11 HYBRID - LACK OF A/C COOLING FORD: 2009 Escape MERCURY: 2009 Mariner ISSUE Some 2009 Escape and Mariner Hybrid vehicles equipped with electronic automatic temperature control (EATC) may exhibit a lack of A/C cooling. Low battery voltage during a previous vehicle start may cause the heating ventilation air conditioning (HVAC) module to function in conventional gasoline mode instead of hybrid vehicle mode. ACTION Follow Service Procedure to correct the condition. SERVICE PROCEDURE 1. To determine if the HVAC control module has defaulted to gasoline mode, first turn off the A/C and Recirculated Air buttons on the HVAC control head. 2. Turn off the HVAC control head. 3. Press the ECON button, the yellow led will light up. 4. Does the A/C and recirculated air buttons also light up when the ECON button is pressed? a. Yes - HVAC module is in gasoline mode, proceed to Step 5. b. No - HVAC module is not in gas mode, this procedure does not apply. 5. Reprogram the HVAC module to the latest calibration using IDS release 71.00 and higher. This new calibration is not included in the VCM 2010.11 DVD. Calibration files may also be obtained at the website. 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 110309A 2009 Escape and Mariner 0.3 Hr. Hybrid: Reprogram The HAVC Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19980 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11-3-9 > Mar > 11 > A/C - Poor Cooling Performance Control Module HVAC: All Technical Service Bulletins A/C - Poor Cooling Performance TSB 11-3-9 03/15/11 HYBRID - LACK OF A/C COOLING FORD: 2009 Escape MERCURY: 2009 Mariner ISSUE Some 2009 Escape and Mariner Hybrid vehicles equipped with electronic automatic temperature control (EATC) may exhibit a lack of A/C cooling. Low battery voltage during a previous vehicle start may cause the heating ventilation air conditioning (HVAC) module to function in conventional gasoline mode instead of hybrid vehicle mode. ACTION Follow Service Procedure to correct the condition. SERVICE PROCEDURE 1. To determine if the HVAC control module has defaulted to gasoline mode, first turn off the A/C and Recirculated Air buttons on the HVAC control head. 2. Turn off the HVAC control head. 3. Press the ECON button, the yellow led will light up. 4. Does the A/C and recirculated air buttons also light up when the ECON button is pressed? a. Yes - HVAC module is in gasoline mode, proceed to Step 5. b. No - HVAC module is not in gas mode, this procedure does not apply. 5. Reprogram the HVAC module to the latest calibration using IDS release 71.00 and higher. This new calibration is not included in the VCM 2010.11 DVD. Calibration files may also be obtained at the website. 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 110309A 2009 Escape and Mariner 0.3 Hr. Hybrid: Reprogram The HAVC Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19980 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 5452 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 5453 Control Module HVAC: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 5454 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5459 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5460 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection Climate Control System Component Tests Ambient Temperature Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 5464 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 5465 Blower Motor Switch: Service and Repair Blower Motor Speed Control Removal and Installation 1. Lower the glove compartment. 2. Disconnect the blower motor speed control electrical connector. 3. Remove the 2 blower motor speed control screws. - To install, tighten to 3 Nm (27 lb-in). 4. Remove the blower motor speed control. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 5469 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 5470 Cabin Temperature Sensor / Switch: Testing and Inspection Climate Control System Component Tests In-Vehicle Temperature Sensor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature and Humidity Sensor Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature and Humidity Sensor In-Vehicle Temperature and Humidity Sensor NOTE: In-vehicle temperature and humidity sensor shown. In-vehicle temperature sensor similar. Removal and Installation 1. NOTICE: Only position the instrument cluster finish panel away from the instrument panel enough to detach the in-vehicle temperature sensor without stressing the attached components. If the instrument cluster finish panel is positioned too far away from the instrument panel, damage to the wire harness or instrument cluster finish panel could result. Detach the instrument cluster finish panel and position it away from the instrument panel to allow access to the in-vehicle temperature sensor. 2. Release the 2 clips and detach the in-vehicle temperature sensor or in-vehicle temperature and humidity sensor. 3. Disconnect the in-vehicle temperature sensor or in-vehicle temperature and humidity sensor electrical connector. 4. Detach the aspirator hose from the venturi at the heater core and evaporator core housing. 5. Detach the aspirator hose from the instrument panel. 6. Remove the in-vehicle temperature sensor or in-vehicle temperature and humidity sensor. 7. NOTE: The venturi must be aligned correctly with the heater core and evaporator core housing for installation. When installing the venturi, it must be pressed into the heater core and evaporator core housing until an audible click is heard to indicated that it is correctly attached. Remove the venturi (if needed). 8. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature and Humidity Sensor > Page 5473 Cabin Temperature Sensor / Switch: Service and Repair Ambient Air Temperature Sensor Ambient Air Temperature Sensor Removal and Installation 1. Detach the ambient air temperature sensor electrical connector from the bumper. 2. Disconnect and remove the ambient air temperature sensor. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5480 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Air Conditioning Evaporator Temperature Sensor / Switch: Description and Operation Air Conditioning Air Conditioning Evaporator Discharge Air Temperature Sensor NOTE: A second (auxiliary) evaporator discharge air temperature sensor is used for the auxiliary evaporator core on hybrid vehicles. The evaporator discharge air temperature sensor contains a thermistor. The resistance of this thermistor varies by a specific amount based on the evaporator discharge air temperature. The HVAC module measures a voltage ratio between the reference voltage it supplies to the sensor and the sensor return voltage to determine this resistance and the associated discharge air temperature. The evaporator discharge air temperature sensor maintains evaporator core temperature and prevents icing of the evaporator core. It does this by signaling the HVAC module to switch off the A/C request signal to the instrument cluster on 2.5L or 3.0L (4V) vehicles, or signaling the PCM to cycle the A/C compressor off when the evaporator discharge air temperature sensor reading falls below acceptable levels. The A/C request or A/C compressor will be switched back on when the evaporator temperature rises above acceptable levels. On hybrid vehicles, the A/C compressor will continue to run and the passenger zone valve will be closed by the PCM if the evaporator discharge air temperature sensor is reading a temperature below acceptable levels, but the TBCM is requesting A/C operation for HVTB cooling. This allows continued refrigerant flow to the auxiliary evaporator core while allowing the front (main) evaporator core to warm to acceptable levels. The evaporator discharge air temperature sensor is located on the heater core and evaporator core housing behind the glove compartment. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Air Conditioning > Page 5483 Evaporator Temperature Sensor / Switch: Description and Operation Engine Control Components Air Conditioning Evaporator Temperature (ACET) Sensor The ACET is connected to the dual automatic temperature control (DATC). Evaporator temperature is transmitted to the PCM from the DATC through the controller area network (CAN). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 5484 Evaporator Temperature Sensor / Switch: Service and Repair Air Conditioning (A/C) Evaporator Discharge Air Temperature Sensor Removal and Installation 1. Lower the glove compartment. 2. Detach the instrument panel wire harness pin-type retainer and position the wire harness away from the evaporator discharge air temperature sensor. 3. Disconnect the A/C evaporator discharge air temperature sensor electrical connector. 4. Gently pry upward and remove the A/C evaporator discharge air temperature sensor. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Locations > Page 5488 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation High Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) High Pressure Switch The A/C high pressure switch is used for additional A/C system pressure control. For refrigerant containment control, the normally closed high pressure contacts open at a predetermined A/C pressure. This results in the A/C turning off, preventing the A/C pressure from rising to a level that would open the A/C high pressure relief valve. For fan control, the normally open medium pressure contacts close at a predetermined A/C pressure. This grounds the ACPSW circuit input to the PCM. The PCM then turns on the high speed fan to help reduce the pressure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Description and Operation Low Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Low Pressure Switch The A/C low pressure switch is used for additional A/C system pressure control. This normally closed switch opens when the refrigerant pressure drops below 152 kPa (22 psi). This results in the A/C turning off, preventing the evaporator from freezing. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions Solar Sensor: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 Solar 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5514 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5515 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5516 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5517 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5518 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5519 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5520 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 5521 Solar Sensor: Description and Operation SOLAR AMPLIFIER (SUNLOAD SENSOR) The solar amplifier (dual-channel sunload sensor), supplies information to the DATC module indicating LH side and RH side sunload. The sunload senor is capable of sensing the intensity and direction of the solar rediation entering the cabin of the car through the windshield for comfort of the driver and front passenger. The smart junction box processes this information to control the air conditioning system. For information on the location and service of the sunload sensor. See: Locations Diagrams By Number, Diagram set 55-004 Auto Climate Control System. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 5522 Solar Sensor: Service and Repair REMOVAL 1. Remove the instrument panel upper finish panel. 2. Disconnect the connector. 3. Remove the A/C sunload sensor from the instrument panel upper finish panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation Air Conditioning Service Gauge Port Valves The high-pressure service gauge port valve is located on the receiver/drier inlet line. The low-pressure service gauge port valve is located on the evaporator outlet line. NOTE: Different valve cores are used for different engine applications. Use only the valve core listed in the Ford Master Parts Catalog for the vehicle and fitting being serviced. The fitting is an integral part of the refrigerant line or component. - Special couplings are required for both the high-side and low-side service gauge ports. - A very small amount of leakage will always be detectable around the Schrader-type valve with the service gauge port valve cap removed, and is considered normal. A new Schrader-type valve core can be installed if the seal leaks excessively. - The service gauge port valve caps are used as primary seals in the refrigerant system to prevent leakage through the Schrader-type valves from reaching the atmosphere. Always install and tighten the A/C service gauge port valve caps to the correct torque after they are removed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions Solar Sensor: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5531 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5532 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5533 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5534 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5535 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5536 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 Solar 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Page 5551 Solar Sensor: Description and Operation SOLAR AMPLIFIER (SUNLOAD SENSOR) The solar amplifier (dual-channel sunload sensor), supplies information to the DATC module indicating LH side and RH side sunload. The sunload senor is capable of sensing the intensity and direction of the solar rediation entering the cabin of the car through the windshield for comfort of the driver and front passenger. The smart junction box processes this information to control the air conditioning system. For information on the location and service of the sunload sensor. See: Locations Diagrams By Number, Diagram set 55-004 Auto Climate Control System. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Page 5552 Solar Sensor: Service and Repair REMOVAL 1. Remove the instrument panel upper finish panel. 2. Disconnect the connector. 3. Remove the A/C sunload sensor from the instrument panel upper finish panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 diagnostic/repair information 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 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 be 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 Occupant Classification Sensor (OCS) System Reset procedure as instructed in the diagnostic/repair information. Refer to the appropriate diagnostic/repair information 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/B1193:00 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. Do not install a new OCSM unless DTC B1231 cannot be cleared. - 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/B1193:00 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 Seat Belt Systems. 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 5558 - Instrument panel and mounting points - Seats and seat mounting points - Safety belts, safety belt buckles and safety belt retractors. For additional information, refer to Seat Belt Systems - 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 (L4-2.5L Hybrid (2009)) 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 5559 Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After A Collision Safety Belt Procedure After a Collision 1. WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 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. Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. Install the new safety belt(s) using the appropriate instructions. Carry out the Functional Test. See: Seat Belt Systems/Testing and Inspection/Component Tests and General Diagnostics Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering Supplemental Restraint System (SRS) Depowering and Repowering Depowering Procedure WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 OFF. 3. At the Smart Junction Box (SJB), located at the RH side of the center console, remove the cover and the RCM fuse 32 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition from OFF to ON. 2. Install RCM fuse 32 (10A) to the SJB and install the cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5565 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 4. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the 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 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5566 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 to OFF. 3. At the Smart Junction Box (SJB) located at the RH side of the center console, remove the cover and the RCM fuse 32 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Using a 3-mm Allen wrench or a suitable tool, place it in the driver air bag module release hole on the underside of the steering wheel. 8. NOTICE: During driver air bag module removal, make sure all 3 driver air bag module hooks are released from the steering wheel wire Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5567 clip. Failure to do so may cause damage to the driver air bag module and or the steering wheel. NOTE: The driver air bag module is removed for clarity. Position the 3-mm Allen wrench or suitable tool against the wire clip and push inward disengaging the wire clip from the 3 driver air bag module hooks. 9. Disconnect the horn electrical connector. Then disconnect the 2 driver air bag module electrical connectors and remove the driver air bag module. 10. Open and lower the glove compartment door. 11. Remove the 2 passenger air bag module bolts. 12. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Failure to follow this instruction may result in vehicle damage, equipment damage, component damage and/or system failure. NOTE: Use care when removing the passenger air bag module from the instrument panel. The passenger air bag module can drop down during removal and the passenger air bag module rear bracket can scratch the front of the instrument panel. Through the glove compartment opening, release the passenger air bag module deployment door clips while pushing the passenger air bag module out of the instrument panel. 13. Remove the passenger air bag module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5568 1. Disconnect the 2 passenger air bag module electrical connectors. 2. Detach the wire harness routing clip and remove the passenger air bag module. 14. From under the rear of the passenger seat, slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 15. Remove the passenger side D-pillar trim panel. 1. Separate the weatherstrip. 2. Pull out and separate the quarter trim panel at the D-pillar trim panel. 3. Pull out to release the retainers and remove the D-pillar trim panel. 16. Disconnect the passenger side safety canopy module electrical connector. 17. Remove the driver side D-pillar trim panel. 1. Separate the weatherstrip. 2. Pull out and separate the quarter trim panel at the D-pillar trim panel. 3. Pull out to release the retainers and remove the D-pillar trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5569 18. Disconnect the driver side safety canopy module electrical connector. 19. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 20. Install RCM fuse 32 (10A) to the SJB. 21. Connect the battery ground cable. Reactivation 1. Remove RCM fuse 32 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 4. Connect the driver side safety canopy module electrical connector. 5. Install the driver side D-pillar trim panel. 1. Engage the D-pillar trim panel to the quarter trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5570 2. Install the D-pillar trim panel. 3. Install the weatherstrip. 6. Connect the passenger side safety canopy module electrical connector. 7. Install the passenger side D-pillar trim panel. 1. Engage the D-pillar trim panel to the quarter trim panel. 2. Install the D-pillar trim panel. 3. Install the weatherstrip. 8. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 9. NOTICE: During passenger air bag module installation, make sure the passenger air bag module wire harness routing clip is attached to the passenger air bag module. Failure to follow this instruction may result in wiring harness damage. NOTICE: The passenger air bag module electrical connectors are unique and cannot be reversed when connected to the passenger air bag module. Match the electrical connector key to the keyway in the passenger air bag module. Do not force the electrical connectors into the passenger air bag module. Failure to follow these instructions may result in component and/or connector damage. Install the passenger air bag module. 1. Connect the 2 passenger air bag module electrical connectors. 2. Attach the wire harness routing clip. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5571 10. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Failure to follow this instruction may result in vehicle damage, equipment damage, component damage and/or system failure. NOTE: During passenger air bag module installation, make sure all the deployment door clips are fully seated into the instrument panel. NOTE: Use care when installing the passenger air bag module in the instrument panel. The passenger air bag module rear bracket can scratch the front of the instrument panel. Position the passenger air bag module and seat the passenger air bag module deployment door clips into the instrument panel. 11. Install the 2 passenger air bag module bolts. - To install, tighten to 8 Nm (71 lb-in). 12. Close the glove compartment door. 13. Install the driver air bag module electrical connectors fully into the driver air bag module. Then connect the horn electrical connector. 14. NOTE: Make sure the driver air bag module wiring harness is routed down and away from the driver air bag module hooks during installation. NOTE: Audible clicks will be heard when the 3 wire clips are seated in the 3 driver air bag module hooks. Align the driver air bag module hooks to the steering wheel and, while pushing inward, seat the 3 driver air bag module hooks to the steering wheel wire clip. - When the 3 driver air bag module hooks are seated in place, gently pull outward at the corners of the driver air bag module to make sure that the 3 hooks are fully seated. There should also be an even gap between the driver air bag module trim cover and the steering wheel. Check the driver air bag module and trim cover for correct movement when applying the horn. 15. Turn the ignition switch from OFF to ON. 16. Install RCM fuse 32 (10A) to the SJB and install the cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5572 17. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 18. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module > Page 5577 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module > Page 5578 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module > Page 5579 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Side Air Bag Module, Left Air Bag: Diagrams Side Air Bag Module, Left Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Side Air Bag Module, Left > Page 5582 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Side Air Bag Module, Left > Page 5583 Air Bag: Diagrams Side Air Bag Module, Right Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Side Air Bag Module, Left > Page 5584 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Side Air Bag Module, Left > Page 5585 Air Bag: Diagrams Passenger Air Bag Module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Side Air Bag Module, Left > Page 5586 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Side Air Bag Module, Left > Page 5587 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger Air Bag: Service and Repair Air Bag Trim Cover - Passenger Air Bag Trim Cover - Passenger Removal WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Do not use any sharp tools to separate the passenger air bag module trim cover from the passenger air bag module canister. Sharp tools may damage the passenger air bag module. Failure to follow this instruction may result in the passenger air bag module deploying incorrectly and increases the risk of serious personal injury or death in a crash. WARNING: Do not unpack or unroll the passenger air bag module soft pack. If the soft pack becomes unpacked or unrolled, install a new passenger air bag module assembly. Failure to follow these instructions may result in the passenger air bag module deploying incorrectly and increases the risk of serious personal injury or death in a crash. WARNING: Do not manipulate or compromise the passenger air bag module hooks during the removal or installation procedure. Failure to follow this instruction may result in the passenger air bag module deploying incorrectly and increases the risk of serious personal injury or death in a crash. 1. Remove the passenger air bag module. For additional information, refer to Passenger Air Bag Module See: Passenger Air Bag Module. 2. Place a mark on top of the passenger air bag module canister for correct installation. 3. Carefully lift the passenger air bag module cover from the bottom of the air bag module canister, separating the windows from the canister hooks. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 5590 4. NOTE: Place an X mark on the old air bag cover to avoid reinstalling. Remove the passenger air bag cover from the canister, separating the top windows from the canister hooks. Installation 1. Place the passenger air bag cover on a clean work surface once it is removed from the shipping package. 2. WARNING: Carefully inspect the passenger air bag trim cover, canister and soft pack before assembly. If any foreign objects are found, remove them before attaching the passenger air bag trim cover to the canister. If the canister or soft pack is damaged, install a new passenger air bag module assembly. Failure to follow this instruction may result in the passenger air bag module deploying incorrectly, which increases the risk of serious personal injury or death in a crash. Match the number of cover windows to the number of canister hooks before attaching the passenger air bag cover to the canister. 3. Match the top of the passenger air bag cover with the canister mark from the removal procedure. 4. Position the canister onto the passenger air bag cover and engage the bottom hooks into the air bag cover windows. 5. Push the top of the passenger air bag cover to engage the top canister hooks. 6. Inspect the passenger air bag cover windows-to-canister hooks to verify that every window has a hook installed and the sides are not tucked or folded against the air bag canister. 7. Install the passenger air bag module. For additional information, refer to Passenger Air Bag Module See: Passenger Air Bag Module. 8. NOTE: The video procedure utilizes a Fusion/Milan passenger air bag module assembly. It also applies to vehicles with similar passenger air bag module designs. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 5591 Air Bag: Service and Repair Driver Air Bag Module Driver Air Bag Module Removal WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Using a 3-mm Allen wrench or a suitable tool, place it in the driver air bag module release hole on the underside of the steering wheel. 3. NOTICE: During driver air bag module removal, make sure all 3 driver air bag module hooks are released from the steering wheel wire clip. Failure to do so may cause damage to the driver air bag module and/or the steering wheel. Position the 3-mm Allen wrench or suitable tool against the wire clip and push inward disengaging the wire clip from the 3 driver air bag module hooks. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 5592 4. Disconnect the horn and 2 driver air bag module electrical connectors and remove the driver air bag module. Installation 1. Connect the driver air bag module and horn electrical connectors. 2. NOTE: Make sure the wiring harness is routed away from the driver air bag module hooks during installation. Align the driver air bag module hooks to the steering wheel and seat the 3 driver air bag module hooks. - When the 3 driver air bag module hooks are seated, gently pull outward at the corners of the driver air bag module to make sure all 3 hooks are fully seated. Check the driver air bag module and trim cover for correct movement when applying the horn. 3. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 5593 Air Bag: Service and Repair Passenger Air Bag Module Passenger Air Bag Module Removal WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. NOTICE: Do not install a new passenger air bag module assembly due to a damaged or discolored passenger air bag cover. The passenger air bag cover can be serviced separately from the passenger air bag module assembly. For additional information, refer to Air Bag Trim Cover Passenger See: Air Bag Trim Cover - Passenger. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Through the glove compartment opening, remove the 2 passenger air bag module bolts. - To install, tighten to 8 Nm (71 lb-in). 3. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the passenger air bag cover. Failure to follow these Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 5594 instructions may result in component damage and/or system failure. NOTE: During passenger air bag module installation, make sure all the passenger air bag cover clips are fully seated into the instrument panel. Through the glove compartment opening, release the passenger air bag module passenger air bag cover clips while pushing the passenger air bag module out of the instrument panel. 4. Remove the passenger air bag module. 1. Disconnect the 2 passenger air bag module electrical connectors. 2. Detach the wire harness routing clip and remove the passenger air bag module. 5. NOTICE: During installation, make sure the passenger air bag module wire harness routing clip is attached to the passenger air bag module. Failure to follow this instruction may result in wiring harness damage. To install, reverse the removal procedure. 6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 5595 Air Bag: Service and Repair Safety Canopy Module Safety Canopy Module NOTE: RH side shown, LH similar. Removal WARNING: Always carry or place a live Safety Canopy(R), or side air curtain module, with the module and tear seam pointed away from your body. Failure to follow this instruction may result in serious personal injury or death in the event of an accidental deployment. WARNING: Anytime the Safety Canopy(R) or side air curtain module has deployed, a new headliner and new A-, B- and C-pillar upper trim panels and attaching hardware must be installed. Remove any other damaged components and hardware and install new components and hardware as needed. Failure to follow these instructions may result in the Safety Canopy(R) or side air curtain module deploying incorrectly and increases the risk of serious personal injury or death in a crash. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 5596 NOTE: There are different safety canopy modules for vehicles equipped with a moon roof and vehicles without a moon roof. The safety canopy modules are NOT interchangeable. If installing a new safety canopy module, the correct safety canopy module MUST be installed for the vehicle application. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering. 2. Remove the headliner. 3. Detach the A-pillar tether pin-type retainer from the A-pillar. 4. Remove the A-pillar tether bolt. - If the vehicle is equipped with a roof opening panel and/or rear window wiper assembly, note the roof opening panel drain hose and/or rear window washer solvent hose position and routing for installation purposes. 5. Remove the 2 safety canopy module bolts located near the top of the A- and B-pillars. 6. Disconnect the safety canopy module electrical connector and detach the connector from the D-pillar. 7. Detach the safety canopy module wiring clip from the roof panel brace. 8. Remove the 2 safety canopy module bolts near the ignitor (between the C- and D-pillars). 9. If equipped with a roof opening panel, disconnect the drain hose. 10. If equipped with a rear window wiper assembly, detach the hose clip and position the hose aside. 11. Remove the remaining 2 safety canopy module bolts (1 near the top of the C-pillar and 1 between the B- and C-pillars). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 5597 12. Lift to unhook the safety canopy module from the C-pillar. 13. Move the safety canopy module forward and release the rear hook. Installation WARNING: Before installing a Safety Canopy(R) or side air curtain module, inspect the roofline for any damage. If necessary, the sheet metal must be reworked to its original condition and structural integrity. Install new fasteners if damaged and remove foreign material. Failure to follow these instructions may result in the Safety Canopy(R) or side air curtain deploying incorrectly, which increases the risk of serious personal injury or death in a crash. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Do not obstruct or place objects in the deployment path of the Safety Canopy(R) or side air curtain module. Failure to follow this instruction may result in the Safety Canopy(R) or side air curtain module deploying incorrectly and increases the risk of serious personal injury or death in a crash. WARNING: Never put any type of fastener or tie strap around any part of a Safety Canopy(R) module, side air curtain module or interior trim panel. This will prevent the Safety Canopy(R) or side air curtain module from deploying correctly. Failure to follow this instruction may increase the risk of serious personal injury or death in a crash. WARNING: Always use new torque-prevailing type J-nuts when installing the Safety Canopy(R) in the vehicle. Use of these J-nuts is mandatory to reduce the risk of loss of fastener effectiveness. Failure to follow this instruction may result in the Safety Canopy(R) module deploying incorrectly and increases the risk of serious personal injury or death in a crash. WARNING: When installing a new headliner on a vehicle equipped with Safety Canopy(R) or side air curtain modules, make sure the headliner has the word AIRBAG on the headliner where it meets each B-pillar trim panel. Otherwise, you have the wrong headliner. Failure to follow this instruction may result in the Safety Canopy(R) or side air curtain module not deploying or deploying incorrectly, increasing the risk of personal injury or death in a crash. 1. WARNING: Always use new torque-prevailing type J-nuts when installing the Safety Canopy(R) in the vehicle. Use of these J-nuts is mandatory to reduce the risk of loss of fastener effectiveness. Failure to follow this instruction may result in the Safety Canopy(R) module deploying incorrectly and increases the risk of serious personal injury or death in a crash. Install new safety canopy module J-nuts. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 5598 2. NOTE: If equipped with a roof opening panel and/or rear window wiper assembly, make sure of correct roof opening panel drain hose and/or rear window solvent hose routing. Position the safety canopy module and insert the rear hook into the sheet metal cavity. 3. Hook the safety canopy module into the C-pillar. 4. Install the 2 safety canopy module bolts located near the top of the A- and B-pillars. - Tighten to 8 Nm (71 lb-in). 5. Attach the A-pillar tether pin-type retainer to the A-pillar. 6. NOTE: If equipped with a roof opening panel and/or rear window wiper assembly, do not pinch the front roof opening panel drain hose and/or rear window washer solvent hose. Install the A-pillar tether bolt. - Tighten to 8 Nm (71 lb-in). 7. Install the 2 safety canopy module bolts near the top of the C-pillar and between the B- and C-pillars. - Tighten to 8 Nm (71 lb-in). 8. If equipped with a rear window wiper assembly, position the hose and attach the hose clip. 9. If equipped with a roof opening panel, connect the roof opening panel rear drain hose. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 5599 10. Connect the safety canopy module electrical connector and attach the connector to the D-pillar. 11. Install the safety canopy module wiring clip to the roof panel brace. 12. Install the remaining 2 rear safety canopy module bolts near the ignitor (between the C- and D-pillars). - Tighten to 8 Nm (71 lb-in). 13. Install the headliner. 14. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 5600 Air Bag: Service and Repair Side Air Bag Module Side Air Bag Module NOTE: Passenger seat shown, driver similar. Removal and Installation WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag material has been exposed, install a new seat side air bag module. Never try to repair the seat side air bag module. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. NOTE: If a side air bag deployment took place, a new seat back pad, trim cover, side air bag module and nuts must be installed. The seat back frame should be replaced if necessary. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. All seats 1. Remove the front seat and depower the SRS. 2. NOTE: Manual seat shown, power seat similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 5601 Remove the inboard seat cushion side shield. 1. Remove the rear screw. - For driver seat, remove the front and rear screws. 2. Push the side shield forward to release. 3. NOTICE: Note the position of the wiring harness, to aid installation. An incorrectly routed wiring harness could become damaged when the seat is moved. Disconnect the side air bag module electrical connector and detach it from the seat track. Detach the 3 wiring harness routing retainers. Seats with manual lumbar adjust 4. Turn the manual lumbar knob clockwise until it stops, releasing all tension on the manual lumbar support cable. 5. Pull and remove the manual lumbar knob. All seats 6. Release the seat backrest trim cover J-clip. 7. NOTICE: Use care when separating the seat backrest trim cover from the hook-and-loop strip. The hook-and-loop strip can be torn from the seat backrest foam pad. Failure to follow this instruction may result in component damage and/or system failure. Place a hand between the seat backrest trim cover and the seat backrest foam pad and carefully separate the hook-and-loop strips. 8. Carefully roll up the seat back trim cover in an inside out fashion to the side air bag module. 9. Release the side air bag module deployment chute J-clip from around the side air bag module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 5602 10. Feed the side air bag module deployment chute and J-clips out through the side air bag module seat backrest foam opening. 11. Continue to roll the seat backrest trim cover up to access the side air bag module. 12. Detach the 2 side air bag module wiring harness retainers from the seat backrest frame. 13. Through the back of the seat backrest, position out the seat backrest foam pad. Remove the 2 side air bag module nuts and remove the side air bag module. Installation WARNING: Inspect the seat side air bag module and mounting surfaces for any damage or foreign material before installing the seat side air bag module. If any damage is found, install new components. If any foreign material is found, remove it. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. WARNING: Before installing the seat side air bag module/deployment chute assembly: - Inspect the side air bag module and mounting surfaces for any damage or foreign material. - Remove any foreign material from the mounting surfaces of the deployment chute, the seat backrest frame mounting bracket and the air bag module cavity in the seat backrest foam pad. - Install new parts if damaged. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. WARNING: If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag material has been exposed, install a new seat side air bag module. Never try to repair the seat side air bag module. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. NOTICE: Make sure the side air bag module wiring harness is not pinched between the side air bag module and the mounting bracket. Failure to follow this instruction may result in wiring harness damage and may cause system failure. All seats Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 5603 1. Install the side air bag module and nuts onto the seat backrest frame mounting bracket. - Tighten to 5 Nm (44 lb-in). 2. Attach the 2 side air bag module wiring harness retainers to the seat backrest frame. 3. Roll down the seat trim cover to the side air bag module. 4. WARNING: Check the seat side air bag deployment chute for damage. The deployment chute must not be repaired. If there is any damage to the deployment chute, a new seat back trim cover and deployment chute must be installed as a unit. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. Feed the side air bag module deployment chute and J-clips back through the side air bag module seat backrest foam opening. 5. WARNING: If the seat side air bag module deployment chute is not correctly positioned and closed, the seat side air bag module may not deploy correctly. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increases the risk of serious personal injury or death in a crash. Install the side air bag module deployment chute and J-clips around the side air bag module and seat backrest frame. 6. Roll the seat backrest trim cover down in position and attach the hook-and-loop strips. 7. Feed the seat backrest trim cover rear J-clip through seat between the seat backrest and seat cushion. 8. Attach the seat backrest trim cover J-clips. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 5604 Seats with manual lumbar adjust 9. Install the manual lumbar control knob. All seats 10. Attach the 3 wiring harness routing retainers. Connect the side air bag module electrical connector and attach it to the seat track. 11. Install the inboard seat cushion side shield and screw. 12. Install the front seat and repower the SRS. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5608 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5609 Air Bag Control Module: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5610 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5611 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5612 Air Bag Control Module: Service and Repair Restraints Control Module (RCM) Removal WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTICE: When installing a new Restraints Control Module (RCM), it is necessary to carry out Programmable Module Installation (PMI). Failure to follow these instructions may result in component damage and/or system failure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: Carrying out Programmable Module Installation (PMI) will not enable the 911 assist option that is disabled. The RCM and Accessory Protocol Interface Module (APIM) must be configured correctly to fully support 911 assist functionality. 1. If installing a new RCM, carry out the steps necessary to prepare for PMI. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5613 2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 3. Remove 2 front LH floor console screws and position the carpet to access the RCM bolts. 4. Remove the RCM access cover. - Remove the scrivet. - Pull forward to release the 2 retainer hooks and remove the RCM access cover. 5. Disengage the lock tab, press and disconnect the small RCM electrical connector. 6. Disconnect the large RCM electrical connector. 1. Pinch the thumb tab and pivot the connector position assurance lever all the way back until it stops. 2. Pull out and disconnect the RCM electrical connector. 7. Remove the 3 bolts and RCM. Installation 1. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. Install the RCM and 3 bolts. Tighten to 11 Nm (97 lb-in). 2. Make sure the connector position assurance lever is in the full release position before attempting to connect the connector. 3. NOTICE: Putting the large Restraints Control Module (RCM) electrical connector into the RCM on an angle can cause bad electrical Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5614 connections and damage components. Position the large RCM electrical connector into the RCM. - NOTICE: Do not push the connector to the point where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the Restraints Control Module (RCM) before using the lever to fully seat the connector. Failure to follow these instructions may result in component damage and/or system failure. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and slight resistance is felt. 4. Connect the RCM electrical connector. - Pivot the connector position assurance lever toward the RCM, drawing the connector in to the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 5. Connect the small RCM electrical connector and push the lock tab in. 6. Install the RCM access cover. - Attach the 2 retainer hooks to the instrument panel brace. - Install the scrivet. 7. Position the carpet into place and install the 2 front LH floor console screws. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5615 8. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 9. When installing a new RCM, carry out the steps necessary to complete Programmable Module Installation (PMI). 10. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn OFF. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Service and Repair Air Bag Deactivation Indicator: Service and Repair Passenger Air Bag Deactivation (PAD) Indicator NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: The Passenger Air Bag Deactivation (PAD) indicator is part of the upper instrument panel center finish panel. 1. NOTE: The ignition must be in the OFF position before disconnecting the PAD indicator electrical connector. Otherwise, a DTC will be set in the Restraints Control Module (RCM) memory and must be cleared before releasing the vehicle to the customer. Turn the ignition OFF and wait at least one minute. 2. NOTE: The passenger air bag module is not shown for clarity. Open and lower the glove compartment door to gain access to the PAD indicator electrical connector. - Disconnect the PAD indicator electrical connector. 3. Pull out to release the retaining clips and detach the instrument panel upper center finish panel. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 5625 Clockspring Assembly / Spiral Cable: Service and Repair Clockspring Removal NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the driver air bag module. For additional information, refer to Driver Air Bag Module See: Air Bag/Service and Repair/Driver Air Bag Module. 3. Tilt the steering wheel in the downward position and lock the tilt handle. 4. NOTICE: To prevent damage to the clockspring make sure the road wheels are in the straight-ahead position. Remove the steering wheel. 5. NOTE: The upper steering column shroud is a 2-piece design and must be removed as an assembly. Release the tabs and remove the 2-piece upper steering column shroud as an assembly. 6. Remove the 3 lower steering column shroud screws. Then release the tilt column locking lever and remove the lower steering column shroud. 7. Disconnect the clockspring electrical connector. 8. Remove the 2 screws and clockspring. Installation 1. NOTICE: If installing a new clockspring, do not remove the clockspring anti-rotation key until the steering wheel is installed. If the Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 5626 anti-rotation key has been removed before installing the steering wheel, the clockspring must be centered. Failure to follow this instruction may result in component damage and/or system failure. Install the clockspring and 2 screws. 2. Connect the clockspring electrical connector. 3. Install the lower steering column shroud and 3 screws. 4. Attach the upper steering column shroud to the lower steering column shroud. 5. WARNING: If the clockspring is not correctly centralized, it may fail prematurely. If in doubt, repeat the centralizing procedure. Failure to follow these instructions may increase the risk of serious personal injury or death in a crash. NOTICE: Do not over-rotate the clockspring inner rotor. The internal ribbon wire is connected to the clockspring rotor. The internal ribbon wire acts as a stop and can be broken from its internal connection. Failure to follow this instruction may result in component damage and/or system failure. If a new clockspring was installed and the anti-rotation key has not been removed proceed to Step 7. If a new clockspring was installed and the anti-rotation key has been removed before the steering wheel is installed or the same clockspring is being installed, rotate the clockspring inner rotor counterclockwise and carefully feel for the ribbon wire to run out of length with slight resistance. Stop rotating the clockspring inner rotor at this point. 6. Starting with the clockspring inner rotor, wiring and connector in the 12 o'clock position, rotate the inner rotor clockwise through 4 revolutions to center the clockspring. Verify that the clockspring is correctly centered by observing that after 4 revolutions: the clockspring rotor window is in the 4 o'clock position and the yellow indicator shows in the window. - the 2 arrows located on the inner and outer rotor of the clockspring line up in the 6 o'clock position. - the clockspring inner rotor, wiring and connector are in the 12 o'clock position. 7. NOTICE: To prevent damage to the clockspring, make sure the road wheels are in the 12 o'clock position to install the steering wheel. Install the steering wheel. 8. If a new clockspring was installed, remove the anti-rotation key. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 5627 9. Install the driver air bag module. For additional information, refer to Driver Air Bag Module See: Air Bag/Service and Repair/Driver Air Bag Module. 10. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5632 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5633 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5634 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5635 Impact Sensor: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5636 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5637 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5638 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5639 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5640 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 5643 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 5644 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 5645 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 5646 Impact Sensor: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 5647 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 5648 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor Impact Sensor: Service and Repair Front Impact Severity Sensor Front Impact Severity Sensor Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Disconnect the front impact severity sensor electrical connector. 3. NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. Remove the nut and front impact severity sensor. - To install, tighten to 11 Nm (97 lb-in). 4. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. To install, reverse the removal procedure. 5. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 5651 Impact Sensor: Service and Repair Side Impact Sensor - First Row, B-Pillar Side Impact Sensor - First Row, B-Pillar NOTE: RH shown, LH similar. Removal WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the B-pillar trim panel. 3. Disconnect the electrical connector. 4. Remove the bolt and side impact sensor. - Tighten to 6 Nm (53 lb-in). 5. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. NOTE: Make sure the B-pillar and side impact severity sensor mating surfaces are clean and free of foreign material. To install, reverse the removal procedure. 6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 5652 Impact Sensor: Service and Repair Side Impact Sensor - Second Row, C-Pillar Side Impact Sensor - Second Row, C-Pillar NOTE: LH shown, RH similar. Removal WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the C-pillar trim panel. 3. Disconnect the electrical connector. 4. Remove the bolt and side impact sensor. - Tighten to 6 Nm (53 lb-in). 5. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. NOTE: Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign material. To install, reverse the removal procedure. 6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 5656 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Locations > Page 5660 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Original Equipment Occupant Classification Sensor - Original Equipment Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5663 Removal NOTE: Occupant Classification Sensor (OCS) system components, seat cushion foam pad, bladder with pressure sensor and OCSM, are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and OCSM) must be installed as an assembly. NOTE: To identify between a production OCS system and a service OCS system (OCS service kit), inspect the electrical connector. A production OCS system allows the disconnect of the OCSM electrical connector. A service OCS system (OCS service kit) has the electrical connector glued to the OCSM. It cannot and should not be disconnected or altered. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the passenger seat and depower the SRS. 2. Disconnect the electrical connectors and detach the wiring clips. 1. Disconnect the Occupant Classification System Module (OCSM) electrical connector. 2. Disconnect the pressure sensor electrical connector. 3. Release the 2 wiring clips on the wiring harness from the seat cushion pan. 4. If equipped with heated seats, disconnect the heated seat relay electrical connector, release the wiring clip on the wiring harness from the seat cushion pan, and disconnect the 2 cushion heater mat electrical connectors. 3. Remove the 4 seat cushion bolts retaining the seat cushion to the seat track. 4. NOTICE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure. Remove the seat cushion and pan assembly. To aid in removal, recline the seat. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5664 5. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad. Detach the seat cushion trim cover J-clips from the seat cushion pan and remove the seat cushion trim cover. 6. Remove the seat cushion foam pad. 7. Bend the retaining tab away from the pressure sensor, then slide the pressure sensor off the bracket. 8. NOTICE: Care must be taken to prevent damage to the seat cushion pan when removing the rivets. Remove the 2 rivets and the OCSM. 9. Remove the 2 pin-type retainers from the OCS bladder and seat cushion pan. 10. Feed the OCS hose and pressure sensor through the seat cushion pan opening and remove as an assembly with the bladder. Installation NOTICE: To prevent system failure, it is necessary to carry out the Occupant Classification Sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. NOTICE: Do not install a new cushion heater mat on a front passenger seat cushion, it is not serviceable separately. If a new cushion heater mat is needed on the front passenger seat, an Occupant Classification Sensor (OCS) system service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. 1. Bend the retaining tab back on the pressure sensor component bracket. 2. NOTICE: Inspect the Occupant Classification Sensor (OCS) bladder, seat cushion pan and support assembly for any foreign objects before installing the OCS to the seat cushion pan. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure. NOTICE: Route the seat Occupant Classification Sensor (OCS) components through the correct seat cushion support opening. Failure to follow these instructions may result in component damage and/or system failure. NOTICE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5665 Feed the OCS components (pressure sensor and hose) through the seat cushion pan opening. 3. Align the OCS bladder to the seat cushion pan. 4. Install the 2 pin-type retainers to the OCS bladder and seat cushion pan. 5. NOTE: Make sure the pressure sensor hose is not kinked during installation. Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining tab is completely engaged. - When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab. 6. Slide the OCSM into the seat cushion pan bracket and install the rivets. - The OCSM must be correctly positioned and securely fastened in place. Failure to do so can set a DTC in the RCM. 7. Position the foam pad to the seat cushion pan. 8. NOTICE: Inspect the seat cushion pad and seat cushion trim cover for any foreign material, before installing the seat cushion trim cover to the seat cushion pad. If any foreign material is found, remove it. Failure to follow these instructions may result in incorrect operation of the Occupant Classification Sensor (OCS) system and may cause system failure. Install the seat cushion trim cover to the seat cushion foam pad and attach the J-clips. 9. NOTICE: Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion trim cover to the seat cushion pad. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect operation of the Occupant Classification Sensor (OCS) system and may cause system failure. Position the seat cushion and pan assembly to the seat track. - To aid in installation, recline the seat backrest. 10. Install the 4 seat track-to-cushion frame bolts. - Tighten to 25 Nm (18 lb-ft). 11. Connect the electrical connectors and wiring clips. 1. Connect the OCSM electrical connector. 2. Connect the pressure sensor electrical connector. 3. Install the 2 wiring clips on the wiring harness to the seat cushion pan. 4. If equipped with heated seats, connect the heated seat relay electrical connector, install the wiring clip on the wiring harness to the seat cushion pan, and connect the 2 cushion heater mat electrical connectors. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5666 12. Install the front passenger seat and repower the SRS. Do not prove out the SRS at this time. 13. WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTICE: To prevent system failure, the following precautions must be taken before carrying out the Occupant Classification Sensor (OCS) system reset: Make sure the voltage to the Occupant Classification System Module (OCSM) is above 8 volts and less than 18 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. Carry out the Occupant Classification Sensor (OCS) system reset. 14. If the first system reset attempt was unsuccessful, carry out a thorough visual inspection of the following and repair any concerns found. - OCS system connector and wiring for damage - Pressure sensor hose for kinks and/or damage - Seat-related wiring harness and body wiring harness terminals and connectors for damage 15. NOTE: The ignition switch must be cycled after the OCS system reset. Carry out a second OCS system reset. If the second attempt is unsuccessful, install a new OCS system service kit. 16. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5667 sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all RCM and OCSM DTCs using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5668 Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Service Kit Occupant Classification Sensor - Service Kit Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5669 Removal WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTE: Occupant Classification Sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and Occupant Classification System Module (OCSM)) must be installed as an assembly. NOTE: To identify between a production OCS system and a service OCS system service kit, inspect the OCSM electrical connector. A production OCS system allows the disconnect of the OCSM electrical connector. A service OCS system (OCS service kit) has the OCSM electrical connector glued to the OCSM. It cannot and should not be disconnected or altered. NOTE: The seat wiring harness will be reused. The OCS service kit connector connects to the seat wiring harness OCSM connector. The pressure sensor seat wiring harness connector will be left unplugged and secured by a tie strap. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the passenger seat and depower the SRS. 2. NOTE: The seat wiring harness will be reused. Disconnect the electrical connector(s) and wiring clips in the following sequence. 1. Disconnect the seat wire harness OCS electrical connector from the service part OCS electrical connector. 2. Release the 2 wiring clips on the wiring harness from the seat cushion pan. 3. If equipped with heated seats, disconnect the heated seat module electrical connector, release the wiring clip on the wiring harness from the seat cushion pan, and disconnect the 2 cushion heater mat electrical connectors. 3. Remove the 4 seat track-to-cushion frame bolts. 4. NOTICE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure. Remove the seat cushion and pan assembly. To aid in removal, recline the seat. 5. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad. Detach the seat cushion trim cover J-clips from the seat cushion pan and remove the seat cushion trim cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5670 6. Bend the retaining tab away from the pressure sensor, then slide the pressure sensor off the bracket. 7. NOTICE: Care must be taken to prevent damage to the seat cushion pan when removing the rivets. Failure to follow these instructions may result in component damage and/or system failure. Remove the 2 rivets and detach the OCSM from the seat cushion pan. 8. Remove the OCS. - Pull all the OCS components (hose, pressure sensor, wire harness, OCSM and connectors) through the seat cushion pan opening. Installation NOTICE: To prevent system failure, it is necessary to carry out the Occupant Classification Sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. NOTICE: Do not install a new cushion heater mat on a front passenger seat cushion, it is not serviceable separately. If a new cushion heater mat is needed on the front passenger seat, an Occupant Classification Sensor (OCS) system service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. 1. Bend the retaining tab back on the pressure sensor component bracket. 2. NOTICE: Inspect the Occupant Classification Sensor (OCS) bladder, seat cushion pan and support assembly for any foreign objects Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5671 before installing the OCS to the seat cushion pan. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure. NOTICE: Route the seat Occupant Classification Sensor (OCS) components through the correct seat cushion support opening. Failure to follow these instructions may result in component damage and/or system failure. NOTICE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Failure to follow these instructions may result in component damage and/or system failure. Feed the OCS service kit components (hose, pressure sensor, OCSM, wire harness and connectors) through the seat cushion pan opening. 3. NOTE: When installing an OCS service kit, the seat wire harness pressure sensor electrical connector is not used. NOTE: Make sure the pressure sensor hose is not kinked during installation. Install the OCS components to the seat cushion pan. 1. Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining tab is completely engaged. - When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab. 2. Slide the OCSM into the seat cushion pan bracket. - The OCSM must be correctly positioned and securely fastened in place. Failure to do so can set a DTC in the RCM. 3. Install the rivets. 4. Attach the seat cushion trim cover J-clips to the seat cushion pan. 5. NOTICE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Failure to follow these instructions may result in component damage and/or system failure. Position the seat cushion and pan assembly to the seat track. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5672 - To aid in installation, recline the seat. 6. Install the 4 seat track-to-cushion frame bolts. - Tighten to 25 Nm (18 lb-ft). 7. NOTE: Do not tie-strap any wiring to the OCS bladder and pressure sensor hose. Connect the electrical connector(s) and wiring clips in the following sequence. 1. Connect the seat wire harness OCS electrical connector to the service part OCS electrical connector. 2. Install the 2 wiring clips on the wiring harness to the cushion pan. 3. If equipped with heated seats, connect the heated seat module electrical connector, install the wiring clip on the wiring harness to the cushion pan, and connect the 2 cushion heater mat electrical connectors. 4. Tie-strap the unused seat wire harness pressure sensor electrical connector safely aside. 5. Tie-strap all loose wire harnesses and electrical connectors safely aside. 8. Install the front passenger seat and repower the SRS. Do not prove out the SRS at this time. 9. WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTICE: To prevent system failure, the following precautions must be taken before carrying out the Occupant Classification Sensor (OCS) system reset: Make sure the voltage to the Occupant Classification System Module (OCSM) is above 8 volts and less than 18 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. Carry out the OCS system reset. 10. If the first system reset attempt was unsuccessful, carry out a thorough visual inspection of the following and repair any concerns found. - OCS system connector and wiring for damage - Pressure sensor hose for kinks and/or damage - Seat-related wiring harness and body wiring harness terminals and connectors for damage 11. NOTE: The ignition switch must be cycled after the OCS system reset. Carry out a second OCS system reset. If the second attempt is unsuccessful, install a new OCS system service kit. 12. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5673 - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all RCM and OCSM DTCs using a scan tool. 13. NOTE: When installing a new OCS, a prepaid return postcard is provided with the new OCS. The serial number for the new part and the Vehicle Identification Number (VIN) must be recorded and sent to Ford Motor Company. Fill out the necessary information on the OCS traceability card and return it along with the complete inoperative OCS to Ford Motor Company. When returning the inoperative OCS, include the following: seat cushion foam pad, bladder, OCSM, pressure sensor (transducer), hose, electrical connectors and wire harness (service part OCS only). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 5677 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 5678 Seat Position Sensor: Service and Repair Seat Position Sensor NOTE: Manual seat shown, power seat similar. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the driver seat. 2. Disconnect the seat position sensor electrical connector. 3. Push the tab ends inward to release the seat position sensor locking clip. Slide the seat position sensor forward to release the 2 hooks from the bracket and remove the seat position sensor. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5683 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5684 Air Bag Control Module: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5685 Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5686 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5687 Air Bag Control Module: Service and Repair Restraints Control Module (RCM) Removal WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTICE: When installing a new Restraints Control Module (RCM), it is necessary to carry out Programmable Module Installation (PMI). Failure to follow these instructions may result in component damage and/or system failure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: Carrying out Programmable Module Installation (PMI) will not enable the 911 assist option that is disabled. The RCM and Accessory Protocol Interface Module (APIM) must be configured correctly to fully support 911 assist functionality. 1. If installing a new RCM, carry out the steps necessary to prepare for PMI. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5688 2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 3. Remove 2 front LH floor console screws and position the carpet to access the RCM bolts. 4. Remove the RCM access cover. - Remove the scrivet. - Pull forward to release the 2 retainer hooks and remove the RCM access cover. 5. Disengage the lock tab, press and disconnect the small RCM electrical connector. 6. Disconnect the large RCM electrical connector. 1. Pinch the thumb tab and pivot the connector position assurance lever all the way back until it stops. 2. Pull out and disconnect the RCM electrical connector. 7. Remove the 3 bolts and RCM. Installation 1. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. Install the RCM and 3 bolts. Tighten to 11 Nm (97 lb-in). 2. Make sure the connector position assurance lever is in the full release position before attempting to connect the connector. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5689 3. NOTICE: Putting the large Restraints Control Module (RCM) electrical connector into the RCM on an angle can cause bad electrical connections and damage components. Position the large RCM electrical connector into the RCM. - NOTICE: Do not push the connector to the point where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the Restraints Control Module (RCM) before using the lever to fully seat the connector. Failure to follow these instructions may result in component damage and/or system failure. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and slight resistance is felt. 4. Connect the RCM electrical connector. - Pivot the connector position assurance lever toward the RCM, drawing the connector in to the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 5. Connect the small RCM electrical connector and push the lock tab in. 6. Install the RCM access cover. - Attach the 2 retainer hooks to the instrument panel brace. - Install the scrivet. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5690 7. Position the carpet into place and install the 2 front LH floor console screws. 8. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 9. When installing a new RCM, carry out the steps necessary to complete Programmable Module Installation (PMI). 10. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn OFF. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 5694 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering Supplemental Restraint System (SRS) Depowering and Repowering Depowering Procedure WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 OFF. 3. At the Smart Junction Box (SJB), located at the RH side of the center console, remove the cover and the RCM fuse 32 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition from OFF to ON. 2. Install RCM fuse 32 (10A) to the SJB and install the cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5700 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 4. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the 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 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5701 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 to OFF. 3. At the Smart Junction Box (SJB) located at the RH side of the center console, remove the cover and the RCM fuse 32 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Using a 3-mm Allen wrench or a suitable tool, place it in the driver air bag module release hole on the underside of the steering wheel. 8. NOTICE: During driver air bag module removal, make sure all 3 driver air bag module hooks are released from the steering wheel wire Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5702 clip. Failure to do so may cause damage to the driver air bag module and or the steering wheel. NOTE: The driver air bag module is removed for clarity. Position the 3-mm Allen wrench or suitable tool against the wire clip and push inward disengaging the wire clip from the 3 driver air bag module hooks. 9. Disconnect the horn electrical connector. Then disconnect the 2 driver air bag module electrical connectors and remove the driver air bag module. 10. Open and lower the glove compartment door. 11. Remove the 2 passenger air bag module bolts. 12. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Failure to follow this instruction may result in vehicle damage, equipment damage, component damage and/or system failure. NOTE: Use care when removing the passenger air bag module from the instrument panel. The passenger air bag module can drop down during removal and the passenger air bag module rear bracket can scratch the front of the instrument panel. Through the glove compartment opening, release the passenger air bag module deployment door clips while pushing the passenger air bag module out of the instrument panel. 13. Remove the passenger air bag module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5703 1. Disconnect the 2 passenger air bag module electrical connectors. 2. Detach the wire harness routing clip and remove the passenger air bag module. 14. From under the rear of the passenger seat, slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 15. Remove the passenger side D-pillar trim panel. 1. Separate the weatherstrip. 2. Pull out and separate the quarter trim panel at the D-pillar trim panel. 3. Pull out to release the retainers and remove the D-pillar trim panel. 16. Disconnect the passenger side safety canopy module electrical connector. 17. Remove the driver side D-pillar trim panel. 1. Separate the weatherstrip. 2. Pull out and separate the quarter trim panel at the D-pillar trim panel. 3. Pull out to release the retainers and remove the D-pillar trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5704 18. Disconnect the driver side safety canopy module electrical connector. 19. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 20. Install RCM fuse 32 (10A) to the SJB. 21. Connect the battery ground cable. Reactivation 1. Remove RCM fuse 32 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 4. Connect the driver side safety canopy module electrical connector. 5. Install the driver side D-pillar trim panel. 1. Engage the D-pillar trim panel to the quarter trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5705 2. Install the D-pillar trim panel. 3. Install the weatherstrip. 6. Connect the passenger side safety canopy module electrical connector. 7. Install the passenger side D-pillar trim panel. 1. Engage the D-pillar trim panel to the quarter trim panel. 2. Install the D-pillar trim panel. 3. Install the weatherstrip. 8. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 9. NOTICE: During passenger air bag module installation, make sure the passenger air bag module wire harness routing clip is attached to the passenger air bag module. Failure to follow this instruction may result in wiring harness damage. NOTICE: The passenger air bag module electrical connectors are unique and cannot be reversed when connected to the passenger air bag module. Match the electrical connector key to the keyway in the passenger air bag module. Do not force the electrical connectors into the passenger air bag module. Failure to follow these instructions may result in component and/or connector damage. Install the passenger air bag module. 1. Connect the 2 passenger air bag module electrical connectors. 2. Attach the wire harness routing clip. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5706 10. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Failure to follow this instruction may result in vehicle damage, equipment damage, component damage and/or system failure. NOTE: During passenger air bag module installation, make sure all the deployment door clips are fully seated into the instrument panel. NOTE: Use care when installing the passenger air bag module in the instrument panel. The passenger air bag module rear bracket can scratch the front of the instrument panel. Position the passenger air bag module and seat the passenger air bag module deployment door clips into the instrument panel. 11. Install the 2 passenger air bag module bolts. - To install, tighten to 8 Nm (71 lb-in). 12. Close the glove compartment door. 13. Install the driver air bag module electrical connectors fully into the driver air bag module. Then connect the horn electrical connector. 14. NOTE: Make sure the driver air bag module wiring harness is routed down and away from the driver air bag module hooks during installation. NOTE: Audible clicks will be heard when the 3 wire clips are seated in the 3 driver air bag module hooks. Align the driver air bag module hooks to the steering wheel and, while pushing inward, seat the 3 driver air bag module hooks to the steering wheel wire clip. - When the 3 driver air bag module hooks are seated in place, gently pull outward at the corners of the driver air bag module to make sure that the 3 hooks are fully seated. There should also be an even gap between the driver air bag module trim cover and the steering wheel. Check the driver air bag module and trim cover for correct movement when applying the horn. 15. Turn the ignition switch from OFF to ON. 16. Install RCM fuse 32 (10A) to the SJB and install the cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 5707 17. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 18. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair Child Seat Tether Attachment: Service and Repair Child Safety Seat Tether Anchor Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Remove the child safety seat tether anchor cover by releasing the top anchor end of the cover first and rocking the cover off of the anchor bolt end. 2. Remove the bolt and child safety seat tether anchor. - To install, tighten to 22 Nm (16 lb-ft). 3. WARNING: Always tighten the child safety seat tether anchor/bolt to specification. Failure to follow this instruction may result in the child's safety seat being incorrectly secured, which increases the risk of serious personal injury or death to the child in a sudden stop or crash. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Page 5712 To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Description and Operation Seat Belt Buckle: Description and Operation Safety Belt System WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. When replacing safety belt buckles and/or retractor assemblies, use only the replacement parts specified in the Ford Customer Service Division Master Parts and Accessories Catalog. Safety Belt Buckles Safety Belt Buckle and Pretensioner The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from the safety belt when deployed. When the pretensioner deploys, the buckle moves downward, removing excess webbing from the lap and shoulder safety belts. If the vehicle is involved in a crash that results in pretensioner deployment, a new safety belt buckle and pretensioner must be installed. For safety belt buckle and pretensioner diagnosis and disposal information, refer to Air Bag Systems. Second row safety belt buckles The second row safety belt buckles can be serviced separately. After any crash, new safety belt systems components (including retractors and buckles) must be installed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Description and Operation > Page 5716 Seat Belt Buckle: Testing and Inspection Safety Belt System Component Test WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. Carry out the appropriate Functional Test(s) as determined in Inspection and Verification. Functional Test - Safety Belt Buckle and Tongue The safety belt buckle and tongue assembly must operate freely during the latching and unlatching function. Fasten the safety belt by inserting the tongue (male portion) into the buckle (female portion). 1. Verify the following during the latching sequence: - Tongue insertion is not hindered by excessive effort. - A click is heard when the safety belt buckle latches the tongue. 2. Verify the system integrity by forcefully pulling on the safety belt webbing. 3. Unlatch the safety belt by fully depressing the safety belt buckle release button and allowing the safety belt to release and retract. 4. Verify the following during the unlatching process: - Push-button depression does not require excessive effort. - The tongue can be removed easily from the buckle. 5. Repeat the above steps 3 times. 6. If the functional test reveals a concern(s), install a new safety belt buckle or safety belt retractor as required. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner Seat Belt Buckle: Service and Repair Safety Belt Buckle and Pretensioner Safety Belt Buckle and Pretensioner Power Seat (Driver Only) Manual Seat NOTE: Passenger seat shown, driver similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 5719 Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition switch is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the seat. 2. Remove the screws and inboard seat cushion side shield. 3. Disconnect the 2 safety belt buckle and pretensioner electrical connectors. 4. NOTE: Note the wire harness routing for correct installation. Detach the side air bag wiring harness pin-type retainer from the safety belt buckle and pretensioner. 5. For the driver seat, remove the seat position sensor wiring harness tie strap from the safety belt buckle and pretensioner. 6. Detach the safety belt buckle pretensioner and buckle switch electrical connectors from the seat track and detach the wiring harness pin-type retainer. 7. Remove the bolt and safety belt buckle and pretensioner. - To install, tighten to 40 Nm (30 lb-ft). 8. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 5720 9. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 5721 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Rear Safety Belt Buckle - Rear Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. NOTE: To access the center and passenger side rear safety belt buckles, pivot the rear seat cushion forward and the rear seat backrest rearward. Remove the bolt and rear center and RH safety belt buckle assembly. - To install, tighten to 48 Nm (35 lb-ft). 2. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 3. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 5726 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 5729 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair Seat Belt Height Adjuster: Service and Repair Safety Belt Shoulder Height Adjuster NOTE: RH side shown, LH similar. Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. NOTE: Inspect the D-ring cover for damage. If the cover is damaged or does not remain closed, install new D-ring cover and bolt. Remove the D-ring cover by squeezing the height adjuster buttons and pulling the cover out at the bottom. 2. Remove the upper B-pillar trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 5733 3. Lower the height adjuster and remove the upper bolt. - To install, tighten to 48 Nm (35 lb-ft). 4. Raise the height adjuster and remove the lower bolt and height adjuster. - To install, tighten to 48 Nm (35 lb-ft). 5. To install, reverse the removal procedure. 6. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Service and Repair Seat Belt Reminder Buzzer: Service and Repair Belt-Minder(R) Deactivating/Activating Preparation 1. Apply the parking brake before deactivating/activating the Belt-Minder(R). 2. Place the gear selector lever in PARK (P) (automatic transaxle) or NEUTRAL (N) (manual transaxle). 3. Place the ignition switch in the OFF position. 4. Close all the vehicle doors. 5. Unbuckle the driver and passenger safety belts. Deactivating/Activating NOTE: The driver and front passenger Belt-Minder(R) are deactivated/activated independently. When deactivating/activating one seating position, do not buckle the other position. 1. Place the ignition switch in the RUN position. (Do not start the engine.) 2. Wait until the safety belt warning lamp turns off (approximately 1 minute). 3. NOTE: Steps 3 must be completed within 50 seconds after the safety belt warning indicator turns off. For seating position being disabled, at a moderate rate, buckle then unbuckle the safety belt 3 times, ending with the safety belt in the unbuckled state. - After this step, the air bar warning indicator illuminates for 3 seconds. 4. Within 7 seconds after the air bar warning indicator turns off, at a moderate rate, buckle then unbuckle the safety belt. - This disables the Belt-Minder(R) feature for that seating position, if it is currently enabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds. - This enables the Belt-Minder(R) feature for that seating position, if it is currently disabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by another flash sequence of 4 times per second for 3 seconds. 5. After confirmation, the deactivation/activation procedure is complete. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Service and Repair Seat Belt Reminder Lamp: Service and Repair Belt-Minder(R) Deactivating/Activating Preparation 1. Apply the parking brake before deactivating/activating the Belt-Minder(R). 2. Place the gear selector lever in PARK (P) (automatic transaxle) or NEUTRAL (N) (manual transaxle). 3. Place the ignition switch in the OFF position. 4. Close all the vehicle doors. 5. Unbuckle the driver and passenger safety belts. Deactivating/Activating NOTE: The driver and front passenger Belt-Minder(R) are deactivated/activated independently. When deactivating/activating one seating position, do not buckle the other position. 1. Place the ignition switch in the RUN position. (Do not start the engine.) 2. Wait until the safety belt warning lamp turns off (approximately 1 minute). 3. NOTE: Steps 3 must be completed within 50 seconds after the safety belt warning indicator turns off. For seating position being disabled, at a moderate rate, buckle then unbuckle the safety belt 3 times, ending with the safety belt in the unbuckled state. - After this step, the air bar warning indicator illuminates for 3 seconds. 4. Within 7 seconds after the air bar warning indicator turns off, at a moderate rate, buckle then unbuckle the safety belt. - This disables the Belt-Minder(R) feature for that seating position, if it is currently enabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds. - This enables the Belt-Minder(R) feature for that seating position, if it is currently disabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by another flash sequence of 4 times per second for 3 seconds. 5. After confirmation, the deactivation/activation procedure is complete. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation Seat Belt Retractor: Description and Operation Safety Belt System WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. When replacing safety belt buckles and/or retractor assemblies, use only the replacement parts specified in the Ford Customer Service Division Master Parts and Accessories Catalog. Safety Belt Retractors - Safety belt retractors with pretensioners (front only) - Dual locking mode Emergency Locking Retractor (ELR) - Automatic Locking Retractor (ALR) (all except driver seat) - BTS (front passenger only) Automatic Locking Retractor (ALR) The ALR mode is used when locking a child seat in an outboard seating position. The ALR mode is automatically activated when the safety belt webbing is fully extracted from the retractor and then allowed to retract. As the safety belt webbing is retracted back onto the spool, an audible clicking sound is made indicating the safety belt retractor is in ALR mode and the safety belt webbing will not pull back out of the safety belt retractor. To disengage the ALR mode, allow the safety belt webbing to fully retract back onto the spool. For testing, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Emergency Locking Retractor (ELR) The ELR is a vehicle-sensitive feature designed to activate and lock the safety belt webbing during braking hard, cornering hard or in an impact of approximately 24 km/h (15 mph). The ELR feature helps to reduce the forward movement of the driver and passengers. For testing, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Testing and Inspection > Functional Test - Safety Belt Retractor Seat Belt Retractor: Testing and Inspection Functional Test - Safety Belt Retractor Safety Belt System Component Test WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. Carry out the appropriate Functional Test(s) as determined in Inspection and Verification. Functional Test - Safety Belt Retractor The safety belt retractor must be freely operational for extraction and retraction of the safety belt webbing between full extension and in-vehicle stowed positions. 1. Extract and retract the safety belt between the full extension and stowed positions. 2. Verify the safety belt retractor operates without excessive effort or binding. 3. Install a new safety belt retractor if any concern is found or the complaint has been verified. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Testing and Inspection > Functional Test - Safety Belt Retractor > Page 5745 Seat Belt Retractor: Testing and Inspection Functional Test - Safety Belt Retractor, Automatic Locking Retractor (ALR) Mode Safety Belt System Component Test WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. Carry out the appropriate Functional Test(s) as determined in Inspection and Verification. Functional Test - Safety Belt Retractor, Automatic Locking Retractor (ALR) Mode 1. Position the seat backrest fully upright (if adjustable). 2. Position the safety belt shoulder height adjuster (if equipped) in the full down or up position. 3. Fasten the safety belt. 4. Pull out the safety belt webbing until the Automatic Locking Retractor (ALR) feature is activated. 5. Allow the safety belt webbing to retract until it stops. 6. Pull on the safety belt webbing to check that the safety belt retractor has remained in the ALR mode. If the safety belt retractor is not locked, install a new safety belt retractor. 7. Unfasten the safety belt and allow the safety belt webbing to retract to its stowed position. 8. Pull out and retract the safety belt webbing to verify the safety belt retractor has converted automatically out of ALR mode. If the safety belt retractor remains locked in the ALR mode, install a new safety belt retractor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Testing and Inspection > Functional Test - Safety Belt Retractor > Page 5746 Seat Belt Retractor: Testing and Inspection Functional Test - Safety Belt Retractor, Road Test Inspection Safety Belt System Component Test WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. Carry out the appropriate Functional Test(s) as determined in Inspection and Verification. Functional Test - Safety Belt Retractor, Road Test Inspection WARNING: The driver and passenger must be prepared to brace themselves in the event the safety belt retractor does not lock. Failure to follow this instruction may result in serious personal injury. NOTE: Make sure there is no excessive slack in the safety belt webbing across the torso during testing. NOTE: Do not jerk on the safety belt webbing when carrying out this test. 1. Test the safety belts in the following sequence: 1. Fasten the safety belts and proceed to a safe area. 2. Attain a speed of 24 km/h (15 mph). 3. WARNING: Apply maximum brake force only on dry concrete or equivalent hard surface, NEVER on wet pavement or gravel. Failure to follow this instruction may result in serious personal injury. Grasp the shoulder harness, lean forward and apply the brakes, making a maximum braking application without a skid. 4. The safety belts should lock up with minimum webbing extension. 5. If there is a lockup of all safety belt retractors being tested, the safety belt retractors are functioning correctly. If any safety belt retractor fails to lock up, install a new safety belt retractor(s). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor Seat Belt Retractor: Service and Repair Safety Belt Retractor Safety Belt Retractor NOTE: Passenger side shown, driver similar. Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor > Page 5749 belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition switch is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures portion of Air Bag Systems. 2. NOTE: Inspect the D-ring cover for damage. If the cover is damaged or does not remain closed, install a new D-ring cover and bolt. Remove the safety belt D-ring bolt cover by squeezing the height adjuster buttons and pulling the cover out at the bottom. 3. Remove the bolt and D-ring. - To install, tighten to 48 Nm (35 lb-ft). 4. Remove the lower B-pillar trim panel. 5. For passenger retractor, disconnect the Belt Tension Sensor (BTS) electrical connector. 6. Remove the safety belt anchor bolt. - To install, tighten to 48 Nm (35 lb-ft). 7. Remove the bolt and safety belt retractor. - To install, tighten to 48 Nm (35 lb-ft). 8. Disconnect the pretensioner electrical connector. 9. Unhook and remove the safety belt retractor. 10. To install, reverse the removal procedure. 11. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures portion of Air Bag Systems. 12. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor > Page 5750 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Rear, Center Safety Belt Retractor - Rear, Center Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor > Page 5751 - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Remove the 60 percent seat backrest. 2. Remove the head restraints. 3. Remove the 2 screws and the latch cover. 4. Remove the 2 seat latch release lever screws. 5. Remove the seat latch release lever. 1. Detach the latch rod from the seat latch release lever. - To aid installation, lock the latch using a flat-blade screwdriver before connecting the latch rod. 2. Remove the seat latch release lever. 6. Remove the 2 screws and safety belt shield. 7. Release the backrest trim cover J-clip. 8. Unzip the backrest trim cover zipper. 9. NOTE: The inboard and outboard head restraint guides are not interchangeable. NOTE: The head restraint guides incorporate an alignment tab that must be aligned correctly when installed. Squeeze together the tip of each head restraint guide and pull the 4 guides out of the frame tube. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor > Page 5752 10. NOTICE: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam pad. Separate the hook-and-loop fasteners and remove the seat backrest trim cover. 11. Remove the backrest foam pad from the backrest frame. 12. Release the seat latch cable from the retractor. 13. Remove the 2 nuts and safety belt guide. - To install, tighten to 40 Nm (30 lb-ft). 14. Remove the nut and safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). 15. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 16. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor > Page 5753 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Rear Safety Belt Retractor - Rear NOTE: RH side shown, LH similar. Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Remove the rear quarter trim panel. 2. Remove the cover and D-ring bolt. - To install, tighten to 48 Nm (35 lb-ft). 3. Remove the safety belt anchor bolt. - To install, tighten to 48 Nm (35 lb-ft). 4. Remove the bolt and rear safety belt retractor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor > Page 5754 - To install, tighten to 48 Nm (35 lb-ft). 5. To install, reverse the removal procedure. 6. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tension Sensor > Component Information > Description and Operation Seat Belt Tension Sensor: Description and Operation Safety Belt System WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. When replacing safety belt buckles and/or retractor assemblies, use only the replacement parts specified in the Ford Customer Service Division Master Parts and Accessories Catalog. Belt Tension Sensor (BTS) The BTS operates as part of the Occupant Classification Sensor (OCS) system on the front passenger seat. To diagnose the BTS, refer to Air Bag Systems. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner > Page 5762 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner > Page 5763 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner > Page 5764 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner > Page 5765 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 5766 Seat Belt Tensioner: Description and Operation Safety Belt System WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. When replacing safety belt buckles and/or retractor assemblies, use only the replacement parts specified in the Ford Customer Service Division Master Parts and Accessories Catalog. Safety Belt Retractors - Safety belt retractors with pretensioners (front only) - Dual locking mode Emergency Locking Retractor (ELR) - Automatic Locking Retractor (ALR) (all except driver seat) - BTS (front passenger only) Automatic Locking Retractor (ALR) The ALR mode is used when locking a child seat in an outboard seating position. The ALR mode is automatically activated when the safety belt webbing is fully extracted from the retractor and then allowed to retract. As the safety belt webbing is retracted back onto the spool, an audible clicking sound is made indicating the safety belt retractor is in ALR mode and the safety belt webbing will not pull back out of the safety belt retractor. To disengage the ALR mode, allow the safety belt webbing to fully retract back onto the spool. For testing, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Emergency Locking Retractor (ELR) The ELR is a vehicle-sensitive feature designed to activate and lock the safety belt webbing during braking hard, cornering hard or in an impact of approximately 24 km/h (15 mph). The ELR feature helps to reduce the forward movement of the driver and passengers. For testing, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5775 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5776 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5777 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5778 Impact Sensor: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5779 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5780 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5781 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5782 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Impact Sensor, Passenger 1 > Page 5783 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 5786 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 5787 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 5788 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 5789 Impact Sensor: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 5790 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver 1 > Page 5791 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor Impact Sensor: Service and Repair Front Impact Severity Sensor Front Impact Severity Sensor Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Disconnect the front impact severity sensor electrical connector. 3. NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. Remove the nut and front impact severity sensor. - To install, tighten to 11 Nm (97 lb-in). 4. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. To install, reverse the removal procedure. 5. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 5794 Impact Sensor: Service and Repair Side Impact Sensor - First Row, B-Pillar Side Impact Sensor - First Row, B-Pillar NOTE: RH shown, LH similar. Removal WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the B-pillar trim panel. 3. Disconnect the electrical connector. 4. Remove the bolt and side impact sensor. - Tighten to 6 Nm (53 lb-in). 5. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. NOTE: Make sure the B-pillar and side impact severity sensor mating surfaces are clean and free of foreign material. To install, reverse the removal procedure. 6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 5795 Impact Sensor: Service and Repair Side Impact Sensor - Second Row, C-Pillar Side Impact Sensor - Second Row, C-Pillar NOTE: LH shown, RH similar. Removal WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the C-pillar trim panel. 3. Disconnect the electrical connector. 4. Remove the bolt and side impact sensor. - Tighten to 6 Nm (53 lb-in). 5. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. NOTE: Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign material. To install, reverse the removal procedure. 6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 5800 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 5803 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Tension Sensor > Component Information > Description and Operation Seat Belt Tension Sensor: Description and Operation Safety Belt System WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. When replacing safety belt buckles and/or retractor assemblies, use only the replacement parts specified in the Ford Customer Service Division Master Parts and Accessories Catalog. Belt Tension Sensor (BTS) The BTS operates as part of the Occupant Classification Sensor (OCS) system on the front passenger seat. To diagnose the BTS, refer to Air Bag Systems. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 5810 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Original Equipment Occupant Classification Sensor - Original Equipment Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5814 5. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad. Detach the seat cushion trim cover J-clips from the seat cushion pan and remove the seat cushion trim cover. 6. Remove the seat cushion foam pad. 7. Bend the retaining tab away from the pressure sensor, then slide the pressure sensor off the bracket. 8. NOTICE: Care must be taken to prevent damage to the seat cushion pan when removing the rivets. Remove the 2 rivets and the OCSM. 9. Remove the 2 pin-type retainers from the OCS bladder and seat cushion pan. 10. Feed the OCS hose and pressure sensor through the seat cushion pan opening and remove as an assembly with the bladder. Installation NOTICE: To prevent system failure, it is necessary to carry out the Occupant Classification Sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. NOTICE: Do not install a new cushion heater mat on a front passenger seat cushion, it is not serviceable separately. If a new cushion heater mat is needed on the front passenger seat, an Occupant Classification Sensor (OCS) system service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. 1. Bend the retaining tab back on the pressure sensor component bracket. 2. NOTICE: Inspect the Occupant Classification Sensor (OCS) bladder, seat cushion pan and support assembly for any foreign objects before installing the OCS to the seat cushion pan. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure. NOTICE: Route the seat Occupant Classification Sensor (OCS) components through the correct seat cushion support opening. Failure to follow these instructions may result in component damage and/or system failure. NOTICE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5815 Feed the OCS components (pressure sensor and hose) through the seat cushion pan opening. 3. Align the OCS bladder to the seat cushion pan. 4. Install the 2 pin-type retainers to the OCS bladder and seat cushion pan. 5. NOTE: Make sure the pressure sensor hose is not kinked during installation. Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining tab is completely engaged. - When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab. 6. Slide the OCSM into the seat cushion pan bracket and install the rivets. - The OCSM must be correctly positioned and securely fastened in place. Failure to do so can set a DTC in the RCM. 7. Position the foam pad to the seat cushion pan. 8. NOTICE: Inspect the seat cushion pad and seat cushion trim cover for any foreign material, before installing the seat cushion trim cover to the seat cushion pad. If any foreign material is found, remove it. Failure to follow these instructions may result in incorrect operation of the Occupant Classification Sensor (OCS) system and may cause system failure. Install the seat cushion trim cover to the seat cushion foam pad and attach the J-clips. 9. NOTICE: Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion trim cover to the seat cushion pad. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect operation of the Occupant Classification Sensor (OCS) system and may cause system failure. Position the seat cushion and pan assembly to the seat track. - To aid in installation, recline the seat backrest. 10. Install the 4 seat track-to-cushion frame bolts. - Tighten to 25 Nm (18 lb-ft). 11. Connect the electrical connectors and wiring clips. 1. Connect the OCSM electrical connector. 2. Connect the pressure sensor electrical connector. 3. Install the 2 wiring clips on the wiring harness to the seat cushion pan. 4. If equipped with heated seats, connect the heated seat relay electrical connector, install the wiring clip on the wiring harness to the seat cushion pan, and connect the 2 cushion heater mat electrical connectors. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5816 12. Install the front passenger seat and repower the SRS. Do not prove out the SRS at this time. 13. WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTICE: To prevent system failure, the following precautions must be taken before carrying out the Occupant Classification Sensor (OCS) system reset: Make sure the voltage to the Occupant Classification System Module (OCSM) is above 8 volts and less than 18 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. Carry out the Occupant Classification Sensor (OCS) system reset. 14. If the first system reset attempt was unsuccessful, carry out a thorough visual inspection of the following and repair any concerns found. - OCS system connector and wiring for damage - Pressure sensor hose for kinks and/or damage - Seat-related wiring harness and body wiring harness terminals and connectors for damage 15. NOTE: The ignition switch must be cycled after the OCS system reset. Carry out a second OCS system reset. If the second attempt is unsuccessful, install a new OCS system service kit. 16. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5817 sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all RCM and OCSM DTCs using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5818 Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Service Kit Occupant Classification Sensor - Service Kit Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5819 Removal WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTE: Occupant Classification Sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and Occupant Classification System Module (OCSM)) must be installed as an assembly. NOTE: To identify between a production OCS system and a service OCS system service kit, inspect the OCSM electrical connector. A production OCS system allows the disconnect of the OCSM electrical connector. A service OCS system (OCS service kit) has the OCSM electrical connector glued to the OCSM. It cannot and should not be disconnected or altered. NOTE: The seat wiring harness will be reused. The OCS service kit connector connects to the seat wiring harness OCSM connector. The pressure sensor seat wiring harness connector will be left unplugged and secured by a tie strap. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the passenger seat and depower the SRS. 2. NOTE: The seat wiring harness will be reused. Disconnect the electrical connector(s) and wiring clips in the following sequence. 1. Disconnect the seat wire harness OCS electrical connector from the service part OCS electrical connector. 2. Release the 2 wiring clips on the wiring harness from the seat cushion pan. 3. If equipped with heated seats, disconnect the heated seat module electrical connector, release the wiring clip on the wiring harness from the seat cushion pan, and disconnect the 2 cushion heater mat electrical connectors. 3. Remove the 4 seat track-to-cushion frame bolts. 4. NOTICE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure. Remove the seat cushion and pan assembly. To aid in removal, recline the seat. 5. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad. Detach the seat cushion trim cover J-clips from the seat cushion pan and remove the seat cushion trim cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5820 6. Bend the retaining tab away from the pressure sensor, then slide the pressure sensor off the bracket. 7. NOTICE: Care must be taken to prevent damage to the seat cushion pan when removing the rivets. Failure to follow these instructions may result in component damage and/or system failure. Remove the 2 rivets and detach the OCSM from the seat cushion pan. 8. Remove the OCS. - Pull all the OCS components (hose, pressure sensor, wire harness, OCSM and connectors) through the seat cushion pan opening. Installation NOTICE: To prevent system failure, it is necessary to carry out the Occupant Classification Sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. NOTICE: Do not install a new cushion heater mat on a front passenger seat cushion, it is not serviceable separately. If a new cushion heater mat is needed on the front passenger seat, an Occupant Classification Sensor (OCS) system service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. 1. Bend the retaining tab back on the pressure sensor component bracket. 2. NOTICE: Inspect the Occupant Classification Sensor (OCS) bladder, seat cushion pan and support assembly for any foreign objects Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5821 before installing the OCS to the seat cushion pan. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure. NOTICE: Route the seat Occupant Classification Sensor (OCS) components through the correct seat cushion support opening. Failure to follow these instructions may result in component damage and/or system failure. NOTICE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Failure to follow these instructions may result in component damage and/or system failure. Feed the OCS service kit components (hose, pressure sensor, OCSM, wire harness and connectors) through the seat cushion pan opening. 3. NOTE: When installing an OCS service kit, the seat wire harness pressure sensor electrical connector is not used. NOTE: Make sure the pressure sensor hose is not kinked during installation. Install the OCS components to the seat cushion pan. 1. Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining tab is completely engaged. - When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab. 2. Slide the OCSM into the seat cushion pan bracket. - The OCSM must be correctly positioned and securely fastened in place. Failure to do so can set a DTC in the RCM. 3. Install the rivets. 4. Attach the seat cushion trim cover J-clips to the seat cushion pan. 5. NOTICE: While positioning the seat cushion pan and Occupant Classification Sensor (OCS) assembly, be careful not to damage any of the components. Failure to follow these instructions may result in component damage and/or system failure. Position the seat cushion and pan assembly to the seat track. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5822 - To aid in installation, recline the seat. 6. Install the 4 seat track-to-cushion frame bolts. - Tighten to 25 Nm (18 lb-ft). 7. NOTE: Do not tie-strap any wiring to the OCS bladder and pressure sensor hose. Connect the electrical connector(s) and wiring clips in the following sequence. 1. Connect the seat wire harness OCS electrical connector to the service part OCS electrical connector. 2. Install the 2 wiring clips on the wiring harness to the cushion pan. 3. If equipped with heated seats, connect the heated seat module electrical connector, install the wiring clip on the wiring harness to the cushion pan, and connect the 2 cushion heater mat electrical connectors. 4. Tie-strap the unused seat wire harness pressure sensor electrical connector safely aside. 5. Tie-strap all loose wire harnesses and electrical connectors safely aside. 8. Install the front passenger seat and repower the SRS. Do not prove out the SRS at this time. 9. WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTICE: To prevent system failure, the following precautions must be taken before carrying out the Occupant Classification Sensor (OCS) system reset: Make sure the voltage to the Occupant Classification System Module (OCSM) is above 8 volts and less than 18 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. Carry out the OCS system reset. 10. If the first system reset attempt was unsuccessful, carry out a thorough visual inspection of the following and repair any concerns found. - OCS system connector and wiring for damage - Pressure sensor hose for kinks and/or damage - Seat-related wiring harness and body wiring harness terminals and connectors for damage 11. NOTE: The ignition switch must be cycled after the OCS system reset. Carry out a second OCS system reset. If the second attempt is unsuccessful, install a new OCS system service kit. 12. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Service and Repair > Occupant Classification Sensor - Original Equipment > Page 5823 - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all RCM and OCSM DTCs using a scan tool. 13. NOTE: When installing a new OCS, a prepaid return postcard is provided with the new OCS. The serial number for the new part and the Vehicle Identification Number (VIN) must be recorded and sent to Ford Motor Company. Fill out the necessary information on the OCS traceability card and return it along with the complete inoperative OCS to Ford Motor Company. When returning the inoperative OCS, include the following: seat cushion foam pad, bladder, OCSM, pressure sensor (transducer), hose, electrical connectors and wire harness (service part OCS only). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 5827 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 5828 Seat Position Sensor: Service and Repair Seat Position Sensor NOTE: Manual seat shown, power seat similar. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the driver seat. 2. Disconnect the seat position sensor electrical connector. 3. Push the tab ends inward to release the seat position sensor locking clip. Slide the seat position sensor forward to release the 2 hooks from the bracket and remove the seat position sensor. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Control Display > Component Information > Technical Service Bulletins > Customer Interest for Accessory Control Display: > 09-11-9 > Jun > 09 > Navigation Radio Time Displays Twice In CD Mode Accessory Control Display: Customer Interest Navigation Radio - Time Displays Twice In CD Mode TSB 09-11-9 06/15/09 NAVIGATION RADIO - WHEN ON IN CD MODE - TIME DISPLAYS TWICE IN THE FDIM FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape and Mariner vehicles equipped with Navigation radio, may exhibit a concern when turning on the audio unit in CD mode. The time will display twice in the Front Display lnter[ace Module (FDIM), both in the center and in the upper right hand corner. Normal operation should be the time displaying in the center of the FDIM when the Navigation unit is off and in the upper right hand corner of the FDIM when the Navigation unit is on. ACTION Reprogram the Front Display Interface Module (FDIM) module to the latest calibration using IDS release 61.04 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration and IDS patch files may also be obtained at the website. 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 091109A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Reprogram The FDIM (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 19C116 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Control Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accessory Control Display: > 09-11-9 > Jun > 09 > Navigation Radio - Time Displays Twice In CD Mode Accessory Control Display: All Technical Service Bulletins Navigation Radio - Time Displays Twice In CD Mode TSB 09-11-9 06/15/09 NAVIGATION RADIO - WHEN ON IN CD MODE - TIME DISPLAYS TWICE IN THE FDIM FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape and Mariner vehicles equipped with Navigation radio, may exhibit a concern when turning on the audio unit in CD mode. The time will display twice in the Front Display lnter[ace Module (FDIM), both in the center and in the upper right hand corner. Normal operation should be the time displaying in the center of the FDIM when the Navigation unit is off and in the upper right hand corner of the FDIM when the Navigation unit is on. ACTION Reprogram the Front Display Interface Module (FDIM) module to the latest calibration using IDS release 61.04 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration and IDS patch files may also be obtained at the website. 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 091109A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Reprogram The FDIM (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 19C116 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Cable - AM/FM Antenna Cable: Service and Repair Antenna Cable - AM/FM Antenna Cable - AM/FM NOTE: View shown from behind instrument panel for clarity. Removal and Installation 1. Remove the Audio Control Module (ACM). For additional information, refer to Audio Control Module (ACM) See: Cellular Phone/Communications Control Module/Service and Repair/Removal and Replacement/Audio Control Module (ACM). 2. Disconnect the AM/FM antenna cable from the AM/FM antenna. 3. NOTE: Lower the glove compartment completely to access the pin-type retainers. Release the AM/FM antenna cable pin-type retainers. 4. Remove the AM/FM antenna cable. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Cable - AM/FM > Page 5853 Antenna Cable: Service and Repair Antenna Cable - Satellite Radio Antenna Cable - Satellite Radio Removal and Installation NOTE: This procedure applies to the vehicles without navigation. For vehicles with navigation, a new satellite radio antenna must be laid over the harness and secured. 1. Remove the RH A-pillar trim panel. 2. Remove the RH sun visor. 3. Lower the front of the headliner enough to gain access to the satellite radio antenna electrical connector. 4. Disconnect the satellite radio antenna electrical connector. 5. Remove the satellite radio antenna. - Disconnect the satellite radio antenna cable-to-Satellite Digital Audio Receiver System (SDARS) module electrical connector. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Cable - AM/FM > Page 5854 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter > Component Information > Service and Repair Alarm System Transmitter: Service and Repair Passive Anti-Theft System (PATS) Transceiver Removal and Installation 1. Remove the steering column opening cover. 2. Remove the 3 screws and the lower steering column shroud. 3. Remove the Passive Anti-Theft System (PATS) transceiver. - Disconnect the electrical connector. 4. NOTE: Replacement of the PATS transceiver does not require the PATS keys to be programmed into the Instrument Cluster (IC) again. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Locations > Page 5862 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 5867 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 5868 Keyless Entry Key-Pad: Testing and Inspection Keyless Entry Keypad Code Programming Programming a Personal Code NOTE: Up to 3 personal codes can be programmed. Once there are 3 personal programmed codes, any attempt to program additional codes will be unsuccessful. 1. Enter the permanent factory keyless entry keypad code. 2. Within 5 seconds, press the 1/2 button on the keypad. 3. Enter the new 5-digit personal keyless entry keypad code. Each number must be entered within 5 seconds of each other. 4. The doors will lock then unlock to confirm the new code is programmed. Erasing the Personal Codes 1. Enter the permanent factory keyless entry keypad code. 2. Within 5 seconds, press the 1/2 button on the keypad and release. 3. Within 5 seconds, press and hold the 1/2 button on the keypad for 2 seconds. 4. All personal codes are now erased and only the permanent factory keyless entry keypad code will work. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 5869 Keyless Entry Key-Pad: Service and Repair Keyless Entry Keypad Removal and Installation 1. Remove the LH front door trim panel. 2. Position the watershield aside. 3. Remove the keypad retaining clip. 4. Remove the keypad from the door. - Disconnect the electrical connector. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry (RKE) Transmitter Programming Remote Keyless Entry (RKE) Transmitter Programming NOTE: This procedure is for programming conventional keyfobs only. The Remote Keyless Entry (RKE) transmitter of the Integrated Keyhead Transmitter (IKT) is programmed automatically during the Passive Anti-Theft System (PATS) programming. For additional information, refer to Key Programming Using Two Programmed Keys or Integrated Keyhead Transmitter Key Programming Using Diagnostic Equipment in Antitheft and Alarm Systems to program the IKT. See: Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys See: Testing and Inspection/Programming and Relearning/Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment NOTE: All RKE transmitters must be programmed at the same time. NOTE: Do not apply the brake pedal during this sequencing, as doing so ends the sequence and the transmitters will not be programmed. 1. Electronically unlock the door locks using the door lock control switch. 2. Cycle the ignition switch from the OFF to the RUN position 8 times in rapid succession (within 10 seconds), with the eighth turn ending in RUN. If the module successfully enters program mode, it locks and then unlocks all the doors. 3. NOTE: If no action is taken within 20 seconds after a transmitter has been programmed, the programming sequence ends (the doors lock and unlock to confirm that programming is complete). Within 20 seconds, press any button on the RKE transmitter to be programmed. The doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position - 20 seconds have passed since entering programming mode or since the last RKE transmitter was programmed - The maximum number (4) of RKE transmitters have been programmed 5. Check the operation of the RKE transmitter. If the door locks do not respond for the programmed RKE transmitter(s), wait several seconds and press the button again. If the door locks still fail to respond, refer to Locks, Latches and Entry Systems See: Body and Frame/Locks/Power Locks/Testing and Inspection. (Make sure that no more than the maximum number of RKE transmitters are attempted to be programmed.) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 5874 Keyless Entry Transmitter: Testing and Inspection Autolock and Auto-Unlock Programming Autolock and Auto-Unlock Programming Autolock Programming Using the Power Door Unlock/Lock Procedure NOTE: The autolock feature can be activated/deactivated independently of the auto-unlock feature. 1. NOTE: Prior to beginning this procedure, make sure that the anti-theft system is not armed, the ignition is in the OFF position, and all the vehicle doors, liftgate and liftgate glass are closed. Close all the doors, the liftgate and the liftgate glass. 2. Confirm that the ignition is in the OFF position. 3. NOTE: Steps 3 through 7 must be carried out within 30 seconds. Turn the ignition from OFF to ON. 4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition from ON to OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition from OFF to ON. The horn will chirp once to indicate the system is in the enable/disable mode. 8. Press the door lock control switch UNLOCK button once, then the LOCK button once to toggle the autolock feature ON/OFF. The horn will chirp once to indicate autolock is disabled. If the horn chirps twice (one short and one long chirp), the autolock feature has been enabled. 9. Turn the ignition to the OFF position to exit the enable/disable mode. The horn will chirp once to indicate the procedure is complete. Autolock Programming Using the Keyless Entry Keypad Procedure (If Equipped) 1. Turn the ignition to the OFF position. 2. Close all the doors, the liftgate and the liftgate glass. 3. Enter the 5-digit permanent entry code on the keyless entry keypad. 4. Within 5 seconds of entering the code, press and hold the 3/4 button on the keypad. While holding the 3/4 button, press the 7/8 button. 5. Release the 7/8 button, then release the 3/4 button. The horn will chirp once to indicate autolock is disabled. If the horn chirps twice (chirp followed by a honk), the autolock feature has been enabled. Autolock Programming Using the Message Center Procedure (If Equipped) 1. To disable/enable the autolock feature, select AUTOLOCK [ON] OFF from the SETUP control for the current display mode. 2. Press the RESET control to turn the autolock ON or OFF. Auto-Unlock Programming Using the Power Door Unlock/Lock Procedure NOTE: The auto-unlock feature can be activated/deactivated independently of the autolock feature. 1. NOTE: Prior to beginning this procedure, make sure that the anti-theft system is not armed, the ignition is in the OFF position, and all the vehicle doors, liftgate and liftgate glass are closed. Close all the doors, the liftgate and the liftgate glass. 2. Confirm that the ignition is in the OFF position. 3. NOTE: Steps 3 through 7 must be carried out within 30 seconds. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 5875 Turn the ignition from OFF to ON. 4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition from ON to OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition from OFF to ON. The horn will chirp once to indicate the system is in the enable/disable mode. 8. Press the door lock control switch LOCK button once, then the UNLOCK button once to toggle the auto-unlock feature ON/OFF. The horn will chirp once to indicate auto-unlock is disabled. If the horn chirps twice (one short and one long chirp), the auto-unlock feature has been enabled. 9. Turn the ignition to the OFF position to exit the enable/disable mode. The horn will chirp once to indicate the procedure is complete. Auto-Unlock Programming Using the Keyless Entry Keypad Procedure (If Equipped) 1. Turn the ignition to the OFF position. 2. Close all the doors, the liftgate and the liftgate glass. 3. Enter the 5-digit permanent entry code on the keyless entry keypad. 4. Within 5 seconds of entering the code, press and hold the 3/4 button on the keypad. While holding the 3/4 button, press and release the 7/8 button 2 times. 5. Release the 3/4 button. The horn will chirp once to indicate auto-unlock is disabled. If the horn chirps twice (chirp followed by a honk), the auto-unlock feature has been enabled. Auto-Unlock Programming Using the Message Center Procedure (If Equipped) 1. To disable/enable the auto-unlock feature, select AUTOUNLOCK [ON] OFF from the SETUP control for the current display mode. 2. Press the RESET control to turn the auto-unlock ON or OFF. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 5876 Keyless Entry Transmitter: Testing and Inspection Perimeter Lighting Feature Programming Perimeter Lighting Feature Programming Programming the Perimeter Lighting Feature Using the Door Lock Control Switch NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the ON position. 2. Press the unlock button on the door lock control switch 3 times. 3. Turn the ignition switch from the ON to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the ON position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The unlock button must be pressed twice within 5 seconds. Within 30 seconds of entering the programming mode, press the unlock button on the door lock control switch twice to enable/disable the perimeter lighting feature. The horn chirps once if the perimeter lighting is disabled or a chirp followed by a honk if the perimeter lighting is enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 5877 Keyless Entry Transmitter: Testing and Inspection Stepped Unlock Programming Stepped Unlock Programming 1. With the ignition switch in the OFF position, press the LOCK and UNLOCK buttons on the Remote Keyless Entry (RKE) transmitter simultaneously for 4 seconds. The turn signals flash twice to indicate the mode change. 2. Repeat Step 1 to enable/disable the stepped unlocking feature. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality Technical Service Bulletin # 10-25-12 Date: 101223 SYNC(R) System - Poor Cell Phone Audio Quality TSB 10-25-12 12/23/10 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Fusion, Taurus X, Taurus 2008-2011 Focus 2008-2010 Edge, Explorer Sport Trac, Explorer 2009-2010 F-150, F-Super Duty, Flex 2009-2011 Escape, Expedition LINCOLN: 2008-2009 MKZ 2009-2011 MKS 2008-2010 MKX 2009-2011 Navigator MERCURY: 2008-2009 Milan, Sable 2008-2010 Mountaineer 2009-2011 Mariner This article supersedes TSB 10-8-4 to update the vehicle model years, Service Procedure and the Part List. The new SYNC service Microphone kit now includes a voltage filter incorporated into the jumper harness. ISSUE Some customers of 2008-2011 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. Parts Block 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 MT102512 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Service Procedure Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5887 The following procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO VEHICLES EQUIPPED WITH HEADLINER MICROPHONE OR DEALER-INSTALLED SYNC SYSTEMS. Go to Step 2 if the vehicle is already equipped with SYNC 3.0 Traffic and Directions or has already been upgraded to latest available consumer interface processor (CIP) level 9L3T-14D544-AE without E911/VHR, 9L2T-14D544-BE with E911/VHR or later versions. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-1 4D544-AE without E9 11 /VHR, 9L2T-14D544-BE with E911/VHR or later version. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement and the service procedure should not be performed. Instead, refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. The jumper harness is equipped with a voltage filter. The filter will need to be wrapped in soft foam 164-R4901 or flock tape 164-R4903 from the Rotunda squeak and rattle kit 164-R4900 to prevent interior squeak/rattle noise. a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place the microphone as close to trim as possible to help minimize visible wire. Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5888 ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable up through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C210. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Escape / Mariner 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped) or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5889 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD182 from C214. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD1 82. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Navigator / Expedition 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped) or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN07, RMNO7 and DMN07 (shield) from C298. Cut the three circuits on the female side of the connector (17C712 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO7 and any two (of the three) black jumper harness wires to RMNO7 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C298. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5890 ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMNO7, RMNO7 and DMNO7 (shield) from C248 (Sport Trac uses C260). Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO7 and any two (of the three) black jumper harness wires to RMNO7 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBPO5 and GD143 from C248. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBPO5 and the remaining black jumper harness wire to GD143. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. F-150 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 from C315 and GD133 from C314. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5891 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. F-Super Duty 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C264. Cut the three circuits on the female side of the connector (17K745 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used 7. Identify circuits CBP41 and GD133 from C264. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Flex Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5892 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Focus 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 10) Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the interior lamp trim. 2. Lower the interior lamp assembly. Refer to WSM, Section 417-02 for additional information. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5893 3. Route microphone cable up through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install interior lamp assembly; ensure microphone cable enters the interior lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CPL6O and GD161 from C934. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CPL6O and the remaining black jumper harness wire to GD161. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Fusion / Milan / MKZ 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBPO2 and GD139 from C913. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBPO2 and the remaining black jumper harness wire to GD139. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time proceed to Final Test / Service Steps. Taurus / Sable / Taurus X Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5894 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN02, RMN02 and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMN02 and any two (of the three) black jumper harness wires to RMN02 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps. MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5895 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN02, RMNO2 and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C911 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM Section 417-01 for additional information. These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO2 and remaining black jumper harness wires to RMNO2 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C911. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps. Final Test / Service Steps 1. After splicing/soldering is complete, apply power to the vehicle and confirm the voltage at the jumper inline connector before connecting the microphone. ^ Jumper blue wire equal 12V positive. ^ Jumper black wire equal ground reference. ^ Jumper yellow wire equal microphone return signal circuit less than IV. 2. Turn off ignition and attach the microphone connector to the jumper harness connector. Make sure that the connector tabs have locked together after connecting. Reversing this connector would cause a failure of the microphone. 3. Bundle and tuck the remainder of the microphone cable over the front of the headliner. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Cellular Phone Microphone: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5900 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5901 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5902 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5903 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5904 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5905 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5906 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5907 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5908 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5909 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5910 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality Technical Service Bulletin # 10-25-12 Date: 101223 SYNC(R) System - Poor Cell Phone Audio Quality TSB 10-25-12 12/23/10 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Fusion, Taurus X, Taurus 2008-2011 Focus 2008-2010 Edge, Explorer Sport Trac, Explorer 2009-2010 F-150, F-Super Duty, Flex 2009-2011 Escape, Expedition LINCOLN: 2008-2009 MKZ 2009-2011 MKS 2008-2010 MKX 2009-2011 Navigator MERCURY: 2008-2009 Milan, Sable 2008-2010 Mountaineer 2009-2011 Mariner This article supersedes TSB 10-8-4 to update the vehicle model years, Service Procedure and the Part List. The new SYNC service Microphone kit now includes a voltage filter incorporated into the jumper harness. ISSUE Some customers of 2008-2011 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. Parts Block 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 MT102512 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Service Procedure Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5916 The following procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO VEHICLES EQUIPPED WITH HEADLINER MICROPHONE OR DEALER-INSTALLED SYNC SYSTEMS. Go to Step 2 if the vehicle is already equipped with SYNC 3.0 Traffic and Directions or has already been upgraded to latest available consumer interface processor (CIP) level 9L3T-14D544-AE without E911/VHR, 9L2T-14D544-BE with E911/VHR or later versions. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-1 4D544-AE without E9 11 /VHR, 9L2T-14D544-BE with E911/VHR or later version. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement and the service procedure should not be performed. Instead, refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. The jumper harness is equipped with a voltage filter. The filter will need to be wrapped in soft foam 164-R4901 or flock tape 164-R4903 from the Rotunda squeak and rattle kit 164-R4900 to prevent interior squeak/rattle noise. a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place the microphone as close to trim as possible to help minimize visible wire. Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5917 ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable up through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C210. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Escape / Mariner 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped) or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5918 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD182 from C214. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD1 82. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Navigator / Expedition 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped) or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN07, RMNO7 and DMN07 (shield) from C298. Cut the three circuits on the female side of the connector (17C712 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO7 and any two (of the three) black jumper harness wires to RMNO7 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C298. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5919 ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMNO7, RMNO7 and DMNO7 (shield) from C248 (Sport Trac uses C260). Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO7 and any two (of the three) black jumper harness wires to RMNO7 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBPO5 and GD143 from C248. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBPO5 and the remaining black jumper harness wire to GD143. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. F-150 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 from C315 and GD133 from C314. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5920 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. F-Super Duty 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C264. Cut the three circuits on the female side of the connector (17K745 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used 7. Identify circuits CBP41 and GD133 from C264. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Flex Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5921 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Focus 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 10) Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the interior lamp trim. 2. Lower the interior lamp assembly. Refer to WSM, Section 417-02 for additional information. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5922 3. Route microphone cable up through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install interior lamp assembly; ensure microphone cable enters the interior lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CPL6O and GD161 from C934. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CPL6O and the remaining black jumper harness wire to GD161. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Fusion / Milan / MKZ 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBPO2 and GD139 from C913. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBPO2 and the remaining black jumper harness wire to GD139. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time proceed to Final Test / Service Steps. Taurus / Sable / Taurus X Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5923 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN02, RMN02 and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMN02 and any two (of the three) black jumper harness wires to RMN02 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps. MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 5924 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN02, RMNO2 and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C911 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM Section 417-01 for additional information. These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO2 and remaining black jumper harness wires to RMNO2 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C911. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps. Final Test / Service Steps 1. After splicing/soldering is complete, apply power to the vehicle and confirm the voltage at the jumper inline connector before connecting the microphone. ^ Jumper blue wire equal 12V positive. ^ Jumper black wire equal ground reference. ^ Jumper yellow wire equal microphone return signal circuit less than IV. 2. Turn off ignition and attach the microphone connector to the jumper harness connector. Make sure that the connector tabs have locked together after connecting. Reversing this connector would cause a failure of the microphone. 3. Bundle and tuck the remainder of the microphone cable over the front of the headliner. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Cellular Phone Microphone: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5929 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5930 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5931 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5932 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5933 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5934 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5935 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5936 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5937 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5938 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 5939 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 10-2-8 > Feb > 10 > SYNC(R) System Defaults To 'Privacy Mode' Communications Control Module: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System Software Update For Various Concerns Communications Control Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System Software Update For Various Concerns > Page 5952 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System Software Update For Various Concerns > Page 5953 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System Functions Inoperative/DTC's Set Communications Control Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System Functions Inoperative/DTC's Set > Page 5958 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System Functions Inoperative/DTC's Set > Page 5959 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: All Technical Service Bulletins SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 5969 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 5970 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 5975 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 5976 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Engine Control Module: All Technical Service Bulletins Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 5982 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0442/P0456/P1450 TSB 10-1-3 02/01/10 HYBRID ONLY - DTCS P0442, P0456 OR P1450 - BUILT ON OR BEFORE 4/6/2009 FORD: 2010 Fusion 2009 Escape MERCURY: 2010 Milan 2009 Mariner This article supersedes TSB 09-9-9 to add a production fix date. ISSUE Some 2009 Escape Hybrid, Mariner Hybrid, 2010 Fusion Hybrid and Milan Hybrid vehicles built on or before 4/6/2009 may exhibit a malfunction indicator light (MIL) accompanied by diagnostic trouble code (DTC) P0442, P0456 or P1450. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Follow the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostic procedures for any DTC code that may be present to ensure the Evaporative Emissions (EVAP) system is functioning properly. 2. When performing EVAP diagnostics on Escape Hybrid and Mariner Hybrid vehicles, the ambient temperature must be greater than 32 °F (0 °C) and the heating ventilation air conditioning (HVAC) system should be set to Defrost. This will provide continuous gasoline engine operation. 3. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 60.11 and higher or 61.01 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 100103A 2010 Fusion Hybrid/Milan 0.3 Hr. Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) 100103A 2009 Escape 0.3 Hr. Hybrid/Mariner Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 5987 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 5993 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 5998 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) > Page 6001 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) Communications Control Module: Diagrams Accessory Protocol Interface Module (APIM) Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6004 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6005 Communications Control Module: Diagrams Audio Control Module (ACM) Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6006 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6007 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures Communications Control Module: Procedures Accessory Protocol Interface Module (APIM) Software Level Check Accessory Protocol Interface Module (APIM) Software Level Check NOTE: This procedure applies to checking the Accessory Protocol Interface Module (APIM) software level. To program the APIM, refer to Accessory Protocol Interface Module (APIM) Programming in Information Bus. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning/Accessory Protocol Interface Module (APIM) Programming 1. Turn the Audio Control Module (ACM) on. 2. Connect the scan tool to the Data Link Connector (DLC). 3. Connect one end of the Universal Serial Bus (USB) male-A to male-A cable to the scan tool. 4. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 5. From the technician service publication website, run On-Line Automotive Service Information System (OASIS) using Quick Start or by manually entering the Vehicle Identification Number (VIN). 6. From the OASIS tab, select the "Sync/APIM" bullet. 7. Select the "Read APIM" button to verify the current Accessory Protocol Interface Module (APIM) software level. - The display shows both the Vehicle Interface Processor (VIP) and Consumer Interface Processor (CIP) software levels. 8. The scan tool displays the following information: - Last Recorded State - Hardware VIN: vehicle identification number associated with the current APIM - Installed date: date the APIM was installed - Radio: currently identified ACM in the vehicle - HW Part No.: APIM hardware part number - Un-installed date: date (if any) the APIM was uninstalled - S/N: APIM serial number - Last Recorded State - Software Date/Time: date and time of last recorded software installation - VIP: VIP software that was installed at that time - CIP: CIP software that was installed at that time Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6010 - Description: a description of the content of the software revision - History - Software Date/Time: date and time of any recorded software installation - VIP: VIP software that was installed at that time - CIP: CIP software that was installed at that time - Description: a description of the content of the software revision - Available Software for Programming Select: allows the software package to be selected - Lineage: the original software release, if the software available is a revision - VIP: VIP software level that is available with the selection - CIP: CIP software level that is available with the selection - Description: a description of the content of the software revision 9. Click a CIP software level to view the device compatibility list associated with the CIP software level, if desired. 10. To exit the APIM software level check, disconnect the scan tool from the DLC and the USB port, or exit the OASIS screen. Audio Control Module (ACM) Self-Diagnostic Mode Audio Control Module (ACM) Self-Diagnostic Mode Audio Systems Without Navigation 1. Turn the Audio Control Module (ACM) on. 2. Operate the audio system in radio tuner (AM/FM) mode. 3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins. - The display indicates each speaker as it is tested. 4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after step 3 by turning the ACM off. Before the speaker walk test is complete, carry out any of the following actions: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6011 5. To exit the self-diagnostic mode, turn the ACM off. Satellite Digital Audio Receiver System (SDARS) Module Electronic Serial Number (ESN) Retrieval - Vehicles Without Navigation 1. Operate the audio system in satellite radio mode. 2. Press and hold the AUX button and preset button 1, simultaneously. - The Satellite Digital Audio Receiver System (SDARS) module Electronic Serial Number (ESN) displays on the screen. 3. Record the SDARS module ESN. 4. Turn the audio system off. Navigation Audio System 1. Turn the Audio Control Module (ACM) on. 2. Operate the audio system in radio tuner (AM/FM) mode. 3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins. - The display indicates each speaker as it is tested. 4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after this step, or by allowing the speaker walk test to complete on its own. Before the speaker walk test is complete, press the "End Test" selection. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6012 5. The following tests are available through the "BEZEL DIAGNOSTICS" menu: 6. To exit the self-diagnostic mode, press the "Exit Diagnostics" selection from the "BEZEL DIAGNOSTICS" menu. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6013 Communications Control Module: Removal and Replacement Audio Control Module (ACM) Audio Control Module (ACM) All Except Navigation Navigation Removal and Installation All vehicles 1. NOTE: Module configuration is only required if a new ACM is being installed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6014 Upload the ACM configuration to the scan tool. 2. Remove the middle instrument panel center finish panel. 3. Remove the 4 ACM screws. - To install, tighten to 2 Nm (18 lb-in) (navigation). - To install, tighten to 1 Nm (9 lb-in) (all except navigation). Navigation 4. Disconnect the antenna and electrical connectors. All except navigation 5. If equipped, remove the 4 screws and the ACM side support brackets. 6. NOTE: Only carry out this step if installing a new ACM. Remove the 2 ACM brackets. All vehicles 7. Remove the ACM. 8. To install, reverse the removal procedure. - Download the configuration information to the ACM. Accessory Protocol Interface Module (APIM) Accessory Protocol Interface Module (APIM) Removal and Installation 1. NOTE: It is necessary to record the current Accessory Protocol Interface Module (APIM) software and hardware level when a new APIM is being installed to make sure that the new component is the same version as the component being replaced. Retrieve and record the current APIM software and hardware level. For additional information, refer to Accessory Protocol Interface Module (APIM) Software Level Check See: Procedures/Accessory Protocol Interface Module (APIM) Software Level Check. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6015 2. Remove the floor console. 3. Disconnect the APIM electrical connector and the Universal Serial Bus (USB) cable electrical connector. 4. Remove the 3 screws and the APIM. - Slide the APIM upward to release the locator clips. 5. To install, reverse the removal procedure. - If a new APIM is being installed, program the APIM to the correct software level. Universal Serial Bus (USB) Cable and Port Universal Serial Bus (USB) Cable and Port Floor Console Trim Panels Universal Serial Bus (USB) Port and Cable Removal and Installation Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6016 NOTE: The original equipment Universal Serial Bus (USB) port and cable is part of the wiring harness. It can only be serviced by overlaying a new USB port and cable. 1. Remove the transmission selector level bezel by pulling straight up. 2. NOTE: Open the floor console storage bin door. Remove the floor console finish panel by pulling straight up. - Disconnect the electrical connector, if necessary. 3. Remove the center instrument panel lower panel by pulling straight back. - Disconnect the electrical connectors. 4. Remove the USB cable and port. - Disconnect the cable from the Accessory Protocol Interface Module (APIM). - Cut the USB port and cable ends and secure them to prevent NVH concerns. 5. To install, reverse the removal procedure. - Secure the new USB port and cable, as necessary, to prevent NVH concerns. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6021 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6022 Parking Assist Control Module: Service and Repair Parking Aid Module (PAM) Removal and Installation 1. NOTE: Module configuration is only required if a new Parking Aid Module (PAM) is being installed. Upload the PAM configuration information to the scan tool. 2. Remove the RH rear quarter trim panel. 3. If replacing the parking aid speaker only, proceed as follows: - Disconnect the electrical connector. - Disengage the clips. - Remove the parking aid speaker. 4. If replacing the PAM, proceed as follows: - Disconnect the electrical connector. - Remove the 2 screws. - Remove the PAM. 5. To install, reverse the removal procedure. - Download the configuration information to the PAM. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6027 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6028 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6029 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 6032 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 6033 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 6034 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 6035 Parking Assist Distance Sensor: Service and Repair Parking Aid Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The rear bumper cover removal is only necessary for access to the outer parking aid sensors. The inner parking aid sensors do not require rear bumper cover removal for access. Remove the rear bumper cover. 3. Press the retaining tabs and remove the parking aid sensor(s). - Disconnect the electrical connectors. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Locations > Page 6039 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Locations > Page 6040 Parking Assist Switch: Service and Repair Parking Aid Switch Removal and Installation 1. Remove the lower instrument panel center finish panel. 2. Press the retaining tabs and remove the parking aid switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams > Page 6047 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Brake Booster Travel Sensor - Hybrid Removal and Installation 1. Disconnect the brake booster travel sensor electrical connector. 2. Release the brake booster travel sensor retainer ring and remove the travel sensor. 3. To install, reverse the removal procedure. 4. Following the scan tool instructions, carry out the multi-calibration routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 6051 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Reset Procedure Driver/Vehicle Information Display: Reset Procedure Oil Life Reset Message Center Configuration Oil Life Reset NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: The XXX's in the steps below represent a numeric value and will display the correct number in percent. For example; OIL LIFE = XXX% may display OIL LIFE = 45%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3. The message center displays OIL LIFE SET TO 100%. Oil Life Start Value Message Center Configuration Oil Life Start Value NOTE: The oil life start value is used to reset the oil life value back to the maximum of approximately 12,000 km (7,500 miles) if the value was previously changed or to lower the value by 10% increments down to 10%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release to adjust new oil life %. 3. NOTE: Once the percent has been lowered to 10%, the next button press starts the sequence over again beginning at 100%. Press and release the RESET button to lower the start value percent until the message center displays the newly desired percent. 4. Press and release the SETUP button to return to the setup menu. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Reset Procedure > Page 6054 Driver/Vehicle Information Display: Removal and Replacement Message Center Switch Removal and Installation All vehicles 1. Remove the LH instrument panel trim panel. Hybrid vehicles 2. Remove the jump start switch screw and position the jump start switch aside. All vehicles 3. Press the retaining tabs and remove the message center switch. - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6063 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6064 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6069 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6070 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6071 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6072 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6073 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6074 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6075 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6076 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6077 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6078 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6079 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6085 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6086 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6091 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6092 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6093 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6094 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6095 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6096 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6097 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6098 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6099 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6100 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6101 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 6106 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 6107 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 6113 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0442/P0456/P1450 TSB 10-1-3 02/01/10 HYBRID ONLY - DTCS P0442, P0456 OR P1450 - BUILT ON OR BEFORE 4/6/2009 FORD: 2010 Fusion 2009 Escape MERCURY: 2010 Milan 2009 Mariner This article supersedes TSB 09-9-9 to add a production fix date. ISSUE Some 2009 Escape Hybrid, Mariner Hybrid, 2010 Fusion Hybrid and Milan Hybrid vehicles built on or before 4/6/2009 may exhibit a malfunction indicator light (MIL) accompanied by diagnostic trouble code (DTC) P0442, P0456 or P1450. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Follow the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostic procedures for any DTC code that may be present to ensure the Evaporative Emissions (EVAP) system is functioning properly. 2. When performing EVAP diagnostics on Escape Hybrid and Mariner Hybrid vehicles, the ambient temperature must be greater than 32 °F (0 °C) and the heating ventilation air conditioning (HVAC) system should be set to Defrost. This will provide continuous gasoline engine operation. 3. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 60.11 and higher or 61.01 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 100103A 2010 Fusion Hybrid/Milan 0.3 Hr. Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) 100103A 2009 Escape 0.3 Hr. Hybrid/Mariner Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 6118 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls Sync Software Programming TSB 08-21-2 10/27/08 SYNC SOFTWARE PROGRAMMING SERVICE TIPS FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus 2009 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator 2009 Mark LT MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE The Sync Accessory Protocol Interface Module (APIM) may require updates to add system enhancements, improve system reliability or address consumer issues. The installation or availability of these updates may be made available in two different methods: ^ Downloadable consumer Service Pack updates available through www.SYNCmyride.com website. ^ APIM Programming Using the Integrated Diagnostic System (IDS). The tool and installation requirements vary between these two methods. This information is being provided to supplement current publications, clarify the requirements needed to reprogram or update the APIM module and provide some additional diagnostic/operational system information. ACTION Refer to the Service Tips for details. SERVICE TIPS Downloadable Consumer Service Pack Updates (Available At www.SyncMyRide.com) These Service Pack Updates are for the Consumer Interface Processor (CIP) side of the APIM module only and are customized for each vehicle based on the last reported APIM software level state. The software download process will bundle the appropriate service packs that are required to achieve the desired state. This is why consumers are asked to report back to the website once they have completed the install. NOTE IT IS NOT RECOMMENDED TO REUSE A DOWNLOADED SERVICE PACK ACROSS MULTIPLE VEHICLES. EACH DOWNLOAD IS PACKAGED ACCORDINGLY TO THE CURRENT STATE OF THE VEHICLE THAT THE DOWNLOAD IS INTENDED FOR. NOTE CONSUMERS DO NOT HAVE THE ABILITY TO REMOVE SERVICE PACK UPDATES ONCE THEY ARE INSTALLED. Steps For Consumer's To Update Sync With The Latest Enhancements 1. Prepare universal serial bus (USB) storage drive by: a. Log into their Sync account and select applications and updates to download. b. Locates a portable USB storage drive that they can take to their vehicle. NOTE FOR OWNERS OF MULTIPLE SYNC-EQUIPPED VEHICLES, IT IS STRONGLY RECOMMENDED TO USE A SEPARATE USB DRIVE FOR EACH SYNC-EQUIPPED VEHICLE. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 6123 Dedicating a USB drive to each vehicle's Sync system helps keep each vehicle's download and installation history current and accurate. In addition, as new Sync features and functionalities become available, consumers may decide to install different features on different vehicles. Dedicated USB drives will help maintain the unique applications for each vehicle. 2. Download files by: a. Plug the USB drive into the computer's USB port. b. Select the USB port being used on the computer. c. Confirm choice of USB storage drive. Then click Next. d. After clicking Next, the files will automatically begin downloading. NOTE DO NOT REMOVE THE USB DRIVE UNTIL THE DOWNLOAD IS COMPLETE. THE SCREEN WILL CONFIRM THAT THE DOWNLOAD IS COMPLETE. e. Safely remove the USB storage drive from the computer's USB port by clicking on the Windows personal computer (PC) Safely Remove Hardware icon at the bottom right of the screen, next to the clock. 3. Install files by: a. Insert USB storage drive into the vehicle's Sync USB port. b. Turn on both, the vehicle and radio. NOTE IT IS RECOMMENDED TO HAVE THE VEHICLE RUNNING (WITH PROPER EXHAUST VENTILATION) AND NOT IN THE ACCESSORY MODE. THIS IS TO ENSURE THE VEHICLE'S BATTERY SUPPLY VOLTAGE REMAINS STABLE DURING THE PROGRAMMING PROCESS. c. Select User Device. d. Select Settings. e. Select Install. Display will change to Begin Installation? f. Select Yes. Installing file - will display on the screen. NOTE DO NOT REMOVE THE USB DRIVE WHILE THE INSTALLATION IS IN PROGRESS. g. Upon completion of downloading of files, Installation Complete will display on the Sync screen. h. The Sync voice will say, Installation complete. Sync may also say, The system will now reboot. Please wait a few moments before using the system. Installation Complete will remain on the Sync display until you exit the installation mode. i. Select the Menu radio button to exit installation mode. j. Remove the USB storage drive. k. Consumer takes their USB storage drive back to their computer to report the successful install. (This feature allows for tracking and determining if the consumers vehicle has a newer version available for downloading or not.) NOTE ADDITIONAL INFORMATION AND DETAILS ARE AVAILABLE ON THE SYNCMYRIDE.COM WEBSITE. REGISTERED SYNC OWNERS WILL SEE VEHICLE SPECIFIC DETAILS AND DIRECTIONS BASED ON THEIR VEHICLE'S OPTION CONTENT. APIM Programming Using IDS This method programs both, the Vehicle Interface Processor (VIP) (through the data link connector) and CIP (through the USB port), portions of the APIM module. NOTE Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 6124 SOFTWARE PACKAGES OBTAINED THROUGH THE PROFESSIONAL TECHNICIAN SOCIETY (PTS) WEBSITE CONTAINS BOTH, VIP AND CIP FILES, THESE DO NOT NEED TO BE INSTALLED IN SEQUENCE LIKE THE CONSUMER DOWNLOAD SERVICE PACK UPDATES, BUT THE ENTIRE PACKAGE MUST BE INSTALLED DURING REPROGRAMMING FOR PROPER OPERATION. THESE SOFTWARE PACKAGES ARE MUCH LARGER IN SIZE AND CONTAIN ALL THE PREVIOUS LEVELS OF ENHANCEMENTS AND UPDATES AS WELL AS ANY ADDITIONAL ENHANCEMENTS AND UPDATES FOR BOTH THE VIP AND CIP PROCESSORS LOCATED IN THE APIM MODULE. NOTE YOU WILL NOT HAVE THE ABILITY TO RESTORE THE PREVIOUS LEVEL OF SYNC OPERATING SOFTWARE ONCE THE APIM MODULE HAS BEEN SUCCESSFULLY UPDATED TO THE NEXT HIGHER LEVEL. NOTE If a new APIM is being installed, install the new APIM before carrying out the following procedure. For additional information, refer to Workshop Manual (WSM), Section 415-00. It is recommended to install a battery charger to the vehicles battery and set at the low charge setting and insure the PC being used for reprogramming is fully charged or plugged into a power source prior to starting the reprogramming process. 1. Turn the ignition key to the On position. 2. Turn the audio control module (ACM) on. 3. Connect the scan tool to the data link connector (DLC). 4. Connect one end of the USB male-A to male-A cable Rotunda part number CCMUSB2-AM-AM-10 (1-800-Rotunda option 6) or equivalent to the scan tool. Compatible cables. (Figures 1) Non-compatible cables. (Figure 2) 5. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 6. From the technician service publication website, run OASIS using Quick Start or by manually entering the vehicle identification number (VIN). 7. From the OASIS tab, select the Sync/APIM bullet. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 6125 8. Select the Read APIM button to verify the current APIM VIP and CIP software levels. NOTE DO NOT DISCONNECT THE VEHICLE COMMUNICATION MODULE (VCM) OR USB CABLES DURING APIM PROGRAMMING. 9. Select the desired software level from the list of available software for programming then select the Program APIM button to begin the APIM programming process. Enter the APIM As-Built data if prompted. a. When only the CIP is being programmed, select cancel when prompted whether or not to program the VIP. b. When the VIP is programmed, the CIP will be programmed automatically. 10. The Sync/APIM application downloads the software into the APIM and displays Programming has been completed successfully. 11. Test the audio system for correct operation. PC requirements for successful reprogramming an APIM module. Ford And LIM Logon Issues - Including Proper Browser Settings The following list will have you check various computer settings to insure your PC is set to the proper configuration for reprogramming an APIM module. NOTE CHANGES TO PC SETTINGS MAY REQUIRE ADMINISTRATOR ACCESS. 1. Do not use a customized browser like AOL, it will not work. Please use Internet Explorer (IE) version 5.5 5P2, 6.0, or higher. 2. Log into website. 3. Navigate to PTS (Professional Technician Society) under the Technical Tools on the Parts and Service tab. 4. Check IE settings by completing the following: a. Preliminary Checks. NOTE THESE INSTRUCTIONS APPLY TO WINDOWS XP MACHINES WITH 5P2 AND IE 6.0 AND ABOVE. (1) Open IE, select Tools at the top of the screen and select Security. (2) Click on the Internet Zone, and find Navigate Sub-frames across different domains and enable this function. (3) Then click OK, system may ask you if you want to accept these function please select Yes. (4) Check the Windows Firewall to make sure it is turned off by: (a) Selecting the Start button. (b) Select Control Panel. (c) Select Windows Firewall (if you do not see the icon, make sure you are using Classic View) and set to off. (5) Check Windows Pop-up Blocker to make sure it is turned off. (a) Open IE. (b) Select Tools at the top of the screen. (c) Select Pop-up Blocker and turn it off. (6) Remove any add-on toolbars such as Google or Yahoo toolbars, as these have additional built in pop-up blockers. (7) Verify that any third party anti-virus, anti-spyware, firewall, or internet security software is temporarily disabled. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 6126 b. Browser Settings - Open IE and select Internet Options under the Tools heading. (1) Select the General tab (2) Select Delete Files and check the Delete all offline content and select OK (3) Select Delete Cookies and click OK (4) Select Clear History and select Yes. (5) Click on the Security tab. (6) Click on the Trusted Sites icon. (7) Click on Sites. (8) In the box below add this website to the zone type in - website. (9) Ensure that required server verification (https:) for all sites in this zone is not checked. (10) Click the Add button. (11) Click the Close button. (12) Re-select the Security tab and select Custom Level. (13) Under Reset Custom Settings, pull down and Reset to: Low, select Reset, select Yes and then OK. NOTE IF RUNNING OASIS ON IE 7.0, RESET TO: MEDIUM-LOW. ALSO, UNDER SETTINGS, SCROLL TO NAVIGATE SUB-FRAMES ACROSS DIFFERENT DOMAINS, SET TO ENABLED AND CLICK OK. (14) Select the Privacy tab, and move the slider to Low. (15) Click on the Advanced, check the box Override automatic cookie handling and check the box to Always allow session cookies' and click OK. (16) Select the Advanced tab and scroll down to HTP 1.1 settings; make sure both options under this section are checked. (17) Scroll down to Security section and make sure the following are checked: (a) Empty Temporary Internet folder when browser is closed. (b) Use SSL 2.0. (c) Use SSL 3.0. (d) Use TLS 1.0. (e) Select Apply and then click on OK. 5. Close all browsers and reboot the computer to have the browser settings take affect properly. The browser settings have now been setup correctly as per Ford Browser settings recommendations. Additional PC Security Settings (May Or May Not Be Required - Depends On Operating System) Changes to PC Security Settings may require Administrator access. 1. Check for Information Bar near top of IE page stating - This website wants to run the following add-ons. 2. Click on Information Bar and select Run ActiveX Controls or Temporarily Allow Pop-ups depending on your operating system. 3. Click on Retry button to refresh information. (May not be required on some operating systems) PC and Server Troubleshooting (Optional) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 6127 ^ If you wish to test another browser for web-based training only, download the free version of Opera at www.Opera.com. ^ For web-based training sound problems, make sure your firewall allows downloading sound file types such as MP3. ^ If you have installed special search and add-on programs such as Gator or Bonzi please remove them. ^ If you have a router, make sure that port 443 is open for Secure Socket Layer (SSL), and ports 80 and 8080 are open for HTTP. ^ Internet access uses a caching or proxy server. Make sure the caching/proxy servers are set to automatically detect settings. Contact your local network administrator and/or your Internet service provider and have them turn off the caching on any and all caching proxy servers for the following: ^ Uniform Resource Locator (URL): www.proservicetech.com or ford website Additional Sync Related Service Tips 1. Performing a Master Reset of the APIM module or removing and restoring the Keep Alive Power circuit fuse (refer to the appropriate wiring manual) for 3-minutes, prior to reprogramming will restore the factory APIM defaults. This can reduce the possibilities of corrupt files, that may have been transferred into the APIM modules memory, from interfering with the reprogramming of the CIP portion of the APIM module. 2. Non-factory installed items that can cause background noise, wind noise or obstruct the voice path to the Sync system's microphone, will reduce the reliability or accuracy of the consumer's voice commands or speech being recognized properly. Some examples may include but are not limited to: ^ Objects hanging from the rear view mirror that may make noise or obstruct the system microphone located on the mirror. ^ Bug shields. ^ Roof mounted accessories. ^ Damaged window moldings. ^ Non-factory installed overhead consoles or sun-visor storage compartments that obstruct the voice path to the systems microphone. (It is recommended when diagnosing voice recognition or phone call sound quality issues to eliminate these types of items before replacing any system components) 3. Remote Starts may prevent the Automatic Discovery Process, of previously paired phones, from connecting with the consumer's phone as it may be outside of the device's Bluetooth reception range. Once the vehicle is started remotely, the Sync system automatically begins to search for previously paired phones; eventually this process will time out if the customers phone does not enter the vehicle prior to the expiration of this internal timer, resulting in the vehicle Sync not automatically recognize the phone and pair with it. If this occurs, once the customer enters the vehicle, the consumer will be required to manually connect the phone through the Sync menus if they would like to use the hands free phone features. NOTE THE CONSUMER WILL NOT BE REQUIRED TO PAIR THE PHONE AGAIN. 4. When Reprogramming APIM modules, it is strongly recommended to use a hard wired internet connection if possible, due to the APIM program file sizes. If a wired internet connection is not available, it is recommended to access the PTS website and download the latest Sync software files from the Tech Central tab prior to reprogramming. This will reduce the overall reprogramming time when you are connected to the vehicle. If error messages appear during the reprogramming process that indicate errors with the VIP or CIP file/image, comparing the saved file/image by checking the file size, between your PC/IDS with the available file/image size indicated in the PTS description can help determine if the file may be corrupt or damaged. If this has occurred or is suspected, re-download the file/image and select Yes when asked Do you want to replace it? 5. Always diagnose and repair any DTC's for the Audio system or any module communication related faults prior to APIM reprogramming. WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 6133 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 6138 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 6143 Dedicating a USB drive to each vehicle's Sync system helps keep each vehicle's download and installation history current and accurate. In addition, as new Sync features and functionalities become available, consumers may decide to install different features on different vehicles. Dedicated USB drives will help maintain the unique applications for each vehicle. 2. Download files by: a. Plug the USB drive into the computer's USB port. b. Select the USB port being used on the computer. c. Confirm choice of USB storage drive. Then click Next. d. After clicking Next, the files will automatically begin downloading. NOTE DO NOT REMOVE THE USB DRIVE UNTIL THE DOWNLOAD IS COMPLETE. THE SCREEN WILL CONFIRM THAT THE DOWNLOAD IS COMPLETE. e. Safely remove the USB storage drive from the computer's USB port by clicking on the Windows personal computer (PC) Safely Remove Hardware icon at the bottom right of the screen, next to the clock. 3. Install files by: a. Insert USB storage drive into the vehicle's Sync USB port. b. Turn on both, the vehicle and radio. NOTE IT IS RECOMMENDED TO HAVE THE VEHICLE RUNNING (WITH PROPER EXHAUST VENTILATION) AND NOT IN THE ACCESSORY MODE. THIS IS TO ENSURE THE VEHICLE'S BATTERY SUPPLY VOLTAGE REMAINS STABLE DURING THE PROGRAMMING PROCESS. c. Select User Device. d. Select Settings. e. Select Install. Display will change to Begin Installation? f. Select Yes. Installing file - will display on the screen. NOTE DO NOT REMOVE THE USB DRIVE WHILE THE INSTALLATION IS IN PROGRESS. g. Upon completion of downloading of files, Installation Complete will display on the Sync screen. h. The Sync voice will say, Installation complete. Sync may also say, The system will now reboot. Please wait a few moments before using the system. Installation Complete will remain on the Sync display until you exit the installation mode. i. Select the Menu radio button to exit installation mode. j. Remove the USB storage drive. k. Consumer takes their USB storage drive back to their computer to report the successful install. (This feature allows for tracking and determining if the consumers vehicle has a newer version available for downloading or not.) NOTE ADDITIONAL INFORMATION AND DETAILS ARE AVAILABLE ON THE SYNCMYRIDE.COM WEBSITE. REGISTERED SYNC OWNERS WILL SEE VEHICLE SPECIFIC DETAILS AND DIRECTIONS BASED ON THEIR VEHICLE'S OPTION CONTENT. APIM Programming Using IDS This method programs both, the Vehicle Interface Processor (VIP) (through the data link connector) and CIP (through the USB port), portions of the APIM module. NOTE Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 6144 SOFTWARE PACKAGES OBTAINED THROUGH THE PROFESSIONAL TECHNICIAN SOCIETY (PTS) WEBSITE CONTAINS BOTH, VIP AND CIP FILES, THESE DO NOT NEED TO BE INSTALLED IN SEQUENCE LIKE THE CONSUMER DOWNLOAD SERVICE PACK UPDATES, BUT THE ENTIRE PACKAGE MUST BE INSTALLED DURING REPROGRAMMING FOR PROPER OPERATION. THESE SOFTWARE PACKAGES ARE MUCH LARGER IN SIZE AND CONTAIN ALL THE PREVIOUS LEVELS OF ENHANCEMENTS AND UPDATES AS WELL AS ANY ADDITIONAL ENHANCEMENTS AND UPDATES FOR BOTH THE VIP AND CIP PROCESSORS LOCATED IN THE APIM MODULE. NOTE YOU WILL NOT HAVE THE ABILITY TO RESTORE THE PREVIOUS LEVEL OF SYNC OPERATING SOFTWARE ONCE THE APIM MODULE HAS BEEN SUCCESSFULLY UPDATED TO THE NEXT HIGHER LEVEL. NOTE If a new APIM is being installed, install the new APIM before carrying out the following procedure. For additional information, refer to Workshop Manual (WSM), Section 415-00. It is recommended to install a battery charger to the vehicles battery and set at the low charge setting and insure the PC being used for reprogramming is fully charged or plugged into a power source prior to starting the reprogramming process. 1. Turn the ignition key to the On position. 2. Turn the audio control module (ACM) on. 3. Connect the scan tool to the data link connector (DLC). 4. Connect one end of the USB male-A to male-A cable Rotunda part number CCMUSB2-AM-AM-10 (1-800-Rotunda option 6) or equivalent to the scan tool. Compatible cables. (Figures 1) Non-compatible cables. (Figure 2) 5. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 6. From the technician service publication website, run OASIS using Quick Start or by manually entering the vehicle identification number (VIN). 7. From the OASIS tab, select the Sync/APIM bullet. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 6145 8. Select the Read APIM button to verify the current APIM VIP and CIP software levels. NOTE DO NOT DISCONNECT THE VEHICLE COMMUNICATION MODULE (VCM) OR USB CABLES DURING APIM PROGRAMMING. 9. Select the desired software level from the list of available software for programming then select the Program APIM button to begin the APIM programming process. Enter the APIM As-Built data if prompted. a. When only the CIP is being programmed, select cancel when prompted whether or not to program the VIP. b. When the VIP is programmed, the CIP will be programmed automatically. 10. The Sync/APIM application downloads the software into the APIM and displays Programming has been completed successfully. 11. Test the audio system for correct operation. PC requirements for successful reprogramming an APIM module. Ford And LIM Logon Issues - Including Proper Browser Settings The following list will have you check various computer settings to insure your PC is set to the proper configuration for reprogramming an APIM module. NOTE CHANGES TO PC SETTINGS MAY REQUIRE ADMINISTRATOR ACCESS. 1. Do not use a customized browser like AOL, it will not work. Please use Internet Explorer (IE) version 5.5 5P2, 6.0, or higher. 2. Log into website. 3. Navigate to PTS (Professional Technician Society) under the Technical Tools on the Parts and Service tab. 4. Check IE settings by completing the following: a. Preliminary Checks. NOTE THESE INSTRUCTIONS APPLY TO WINDOWS XP MACHINES WITH 5P2 AND IE 6.0 AND ABOVE. (1) Open IE, select Tools at the top of the screen and select Security. (2) Click on the Internet Zone, and find Navigate Sub-frames across different domains and enable this function. (3) Then click OK, system may ask you if you want to accept these function please select Yes. (4) Check the Windows Firewall to make sure it is turned off by: (a) Selecting the Start button. (b) Select Control Panel. (c) Select Windows Firewall (if you do not see the icon, make sure you are using Classic View) and set to off. (5) Check Windows Pop-up Blocker to make sure it is turned off. (a) Open IE. (b) Select Tools at the top of the screen. (c) Select Pop-up Blocker and turn it off. (6) Remove any add-on toolbars such as Google or Yahoo toolbars, as these have additional built in pop-up blockers. (7) Verify that any third party anti-virus, anti-spyware, firewall, or internet security software is temporarily disabled. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 6146 b. Browser Settings - Open IE and select Internet Options under the Tools heading. (1) Select the General tab (2) Select Delete Files and check the Delete all offline content and select OK (3) Select Delete Cookies and click OK (4) Select Clear History and select Yes. (5) Click on the Security tab. (6) Click on the Trusted Sites icon. (7) Click on Sites. (8) In the box below add this website to the zone type in - website. (9) Ensure that required server verification (https:) for all sites in this zone is not checked. (10) Click the Add button. (11) Click the Close button. (12) Re-select the Security tab and select Custom Level. (13) Under Reset Custom Settings, pull down and Reset to: Low, select Reset, select Yes and then OK. NOTE IF RUNNING OASIS ON IE 7.0, RESET TO: MEDIUM-LOW. ALSO, UNDER SETTINGS, SCROLL TO NAVIGATE SUB-FRAMES ACROSS DIFFERENT DOMAINS, SET TO ENABLED AND CLICK OK. (14) Select the Privacy tab, and move the slider to Low. (15) Click on the Advanced, check the box Override automatic cookie handling and check the box to Always allow session cookies' and click OK. (16) Select the Advanced tab and scroll down to HTP 1.1 settings; make sure both options under this section are checked. (17) Scroll down to Security section and make sure the following are checked: (a) Empty Temporary Internet folder when browser is closed. (b) Use SSL 2.0. (c) Use SSL 3.0. (d) Use TLS 1.0. (e) Select Apply and then click on OK. 5. Close all browsers and reboot the computer to have the browser settings take affect properly. The browser settings have now been setup correctly as per Ford Browser settings recommendations. Additional PC Security Settings (May Or May Not Be Required - Depends On Operating System) Changes to PC Security Settings may require Administrator access. 1. Check for Information Bar near top of IE page stating - This website wants to run the following add-ons. 2. Click on Information Bar and select Run ActiveX Controls or Temporarily Allow Pop-ups depending on your operating system. 3. Click on Retry button to refresh information. (May not be required on some operating systems) PC and Server Troubleshooting (Optional) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 6147 ^ If you wish to test another browser for web-based training only, download the free version of Opera at www.Opera.com. ^ For web-based training sound problems, make sure your firewall allows downloading sound file types such as MP3. ^ If you have installed special search and add-on programs such as Gator or Bonzi please remove them. ^ If you have a router, make sure that port 443 is open for Secure Socket Layer (SSL), and ports 80 and 8080 are open for HTTP. ^ Internet access uses a caching or proxy server. Make sure the caching/proxy servers are set to automatically detect settings. Contact your local network administrator and/or your Internet service provider and have them turn off the caching on any and all caching proxy servers for the following: ^ Uniform Resource Locator (URL): www.proservicetech.com or ford website Additional Sync Related Service Tips 1. Performing a Master Reset of the APIM module or removing and restoring the Keep Alive Power circuit fuse (refer to the appropriate wiring manual) for 3-minutes, prior to reprogramming will restore the factory APIM defaults. This can reduce the possibilities of corrupt files, that may have been transferred into the APIM modules memory, from interfering with the reprogramming of the CIP portion of the APIM module. 2. Non-factory installed items that can cause background noise, wind noise or obstruct the voice path to the Sync system's microphone, will reduce the reliability or accuracy of the consumer's voice commands or speech being recognized properly. Some examples may include but are not limited to: ^ Objects hanging from the rear view mirror that may make noise or obstruct the system microphone located on the mirror. ^ Bug shields. ^ Roof mounted accessories. ^ Damaged window moldings. ^ Non-factory installed overhead consoles or sun-visor storage compartments that obstruct the voice path to the systems microphone. (It is recommended when diagnosing voice recognition or phone call sound quality issues to eliminate these types of items before replacing any system components) 3. Remote Starts may prevent the Automatic Discovery Process, of previously paired phones, from connecting with the consumer's phone as it may be outside of the device's Bluetooth reception range. Once the vehicle is started remotely, the Sync system automatically begins to search for previously paired phones; eventually this process will time out if the customers phone does not enter the vehicle prior to the expiration of this internal timer, resulting in the vehicle Sync not automatically recognize the phone and pair with it. If this occurs, once the customer enters the vehicle, the consumer will be required to manually connect the phone through the Sync menus if they would like to use the hands free phone features. NOTE THE CONSUMER WILL NOT BE REQUIRED TO PAIR THE PHONE AGAIN. 4. When Reprogramming APIM modules, it is strongly recommended to use a hard wired internet connection if possible, due to the APIM program file sizes. If a wired internet connection is not available, it is recommended to access the PTS website and download the latest Sync software files from the Tech Central tab prior to reprogramming. This will reduce the overall reprogramming time when you are connected to the vehicle. If error messages appear during the reprogramming process that indicate errors with the VIP or CIP file/image, comparing the saved file/image by checking the file size, between your PC/IDS with the available file/image size indicated in the PTS description can help determine if the file may be corrupt or damaged. If this has occurred or is suspected, re-download the file/image and select Yes when asked Do you want to replace it? 5. Always diagnose and repair any DTC's for the Audio system or any module communication related faults prior to APIM reprogramming. WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams > Page 6152 Auxiliary Input / Output Jack: Service and Repair Audio Input Jack Removal and Installation 1. NOTE: Pull straight back to disengage the clips. Remove the instrument panel lower panel. - Disconnect the electrical connector(s). 2. Release the tabs and remove the audio input jack. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Technical Service Bulletins > Customer Interest for Entertainment System Control Module: > 09-11-9 > Jun > 09 > Navigation Radio - Time Displays Twice In CD Mode Entertainment System Control Module: Customer Interest Navigation Radio - Time Displays Twice In CD Mode TSB 09-11-9 06/15/09 NAVIGATION RADIO - WHEN ON IN CD MODE - TIME DISPLAYS TWICE IN THE FDIM FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape and Mariner vehicles equipped with Navigation radio, may exhibit a concern when turning on the audio unit in CD mode. The time will display twice in the Front Display lnter[ace Module (FDIM), both in the center and in the upper right hand corner. Normal operation should be the time displaying in the center of the FDIM when the Navigation unit is off and in the upper right hand corner of the FDIM when the Navigation unit is on. ACTION Reprogram the Front Display Interface Module (FDIM) module to the latest calibration using IDS release 61.04 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration and IDS patch files may also be obtained at the website. 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 091109A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Reprogram The FDIM (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 19C116 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Entertainment System Control Module: > 09-11-9 > Jun > 09 > Navigation Radio - Time Displays Twice In CD Mode Entertainment System Control Module: All Technical Service Bulletins Navigation Radio - Time Displays Twice In CD Mode TSB 09-11-9 06/15/09 NAVIGATION RADIO - WHEN ON IN CD MODE - TIME DISPLAYS TWICE IN THE FDIM FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape and Mariner vehicles equipped with Navigation radio, may exhibit a concern when turning on the audio unit in CD mode. The time will display twice in the Front Display lnter[ace Module (FDIM), both in the center and in the upper right hand corner. Normal operation should be the time displaying in the center of the FDIM when the Navigation unit is off and in the upper right hand corner of the FDIM when the Navigation unit is on. ACTION Reprogram the Front Display Interface Module (FDIM) module to the latest calibration using IDS release 61.04 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration and IDS patch files may also be obtained at the website. 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 091109A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Reprogram The FDIM (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 19C116 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Panel > Component Information > Service and Repair > Front Display Interface Module (FDIM) Entertainment System Control Panel: Service and Repair Front Display Interface Module (FDIM) Front Display Interface Module (FDIM) Removal and Installation 1. NOTE: Module configuration is only required if a new Front Display Interface Module (FDIM) is being installed. Upload the FDIM configuration information to the scan tool. 2. Remove the instrument panel upper finish panel by pulling straight back. 3. Remove the 4 FDIM screws. 4. Remove the FDIM. - Disconnect the electrical connector. 5. To install, reverse the removal procedure. - Download the configuration information to the FDIM. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Panel > Component Information > Service and Repair > Front Display Interface Module (FDIM) > Page 6170 Entertainment System Control Panel: Service and Repair Front Controls Interface Module (FCIM) Front Controls Interface Module (FCIM) Removal and Installation NOTE: If the Front Controls Interface Module (FCIM) is being replaced, it must be replaced as an assembly with the middle center instrument panel center finish panel. However, the middle center instrument panel center finish panel can be replaced individually if the FCIM does not need to be replaced. 1. Remove the Audio Control Module (ACM). For additional information, refer to Audio Control Module (ACM) See: Cellular Phone/Communications Control Module/Service and Repair/Removal and Replacement/Audio Control Module (ACM). 2. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6180 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6181 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6187 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6188 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6198 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6199 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R) System Software Update For Various Concerns Navigation Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R) System Software Update For Various Concerns > Page 6205 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R) System Software Update For Various Concerns > Page 6206 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 09-24-2 > Dec > 09 > Steering/Suspension - Front End Click/Pop On Bumps Stabilizer Link: All Technical Service Bulletins Steering/Suspension - Front End Click/Pop On Bumps TSB 09-24-2 12/14/09 CLICK/POP NOISE FROM FRONT STABILIZER BAR END LINK AREA WHEN DRIVING OVER BUMPS - BUILT ON OR BEFORE 10/9/2009 FORD: 2005-2010 Escape MERCURY: 2005-2010 Mariner ISSUE Some 2005-2010 Escape, Escape Hybrid, Mariner and 2006-2010 Mariner Hybrid vehicles built on or before 10/9/2009 may exhibit a click/pop noise from the front end when going over bumps. This may be due to the stabilizer bar end link to strut (upper) attachment. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE 1. Using chassis ears, can the click/pop noise be isolated to the stabilizer bar end links? a. No - Do not continue with this procedure. Follow normal Workshop Manual (WSM), Section 204-00 diagnostics. b. Yes - Proceed to Step 2. 2. Inspect the stabilizer bar end link to strut (upper) attachment nuts for signs of looseness. Is any evidence present of loose upper nuts? a. No - Replace stabilizer bar end links and install revised upper nuts per WSM, Section 204-01. NOTE THE REVISED, TALLER NUTS CANNOT BE INSTALLED ON THE STABILIZER BAR END LINK LOWER ATTACHMENT. b. Yes - Remove and replace both upper nuts with revised, taller nuts per WSM, Section 204-01. Torque to 46 lb-ft (63 N.m). It is not necessary to replace the stabilizer bar end link. Parts Block 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 092402A 2005-2010 Escape, 1.1 Hrs. Mariner, Escape Hybrid, 2006-2010 Mariner Hybrid: Diagnose With Chassis Ears And Road Test, Inspect Stabilizer Bar End Links, Replace Four (4) Stabilizer End Link Nuts Or Stabilizer Bar End Links (Do Not Use With Any Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 09-24-2 > Dec > 09 > Steering/Suspension - Front End Click/Pop On Bumps > Page 6212 Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5K483 24 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 09-24-2 > Dec > 09 > Steering/Suspension - Front End Click/Pop On Bumps > Page 6218 Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5K483 24 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer Amplifier Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer Amplifier > Page 6224 Amplifier: Diagrams Audio Amplifier Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Subwoofer Amplifier Amplifier: Service and Repair Subwoofer Amplifier Subwoofer Amplifier Removal and Installation 1. Disconnect the battery. 2. Remove the RH rear quarter trim panel. 3. Disconnect the subwoofer amplifier electrical connector. 4. Remove the 4 screws and the subwoofer amplifier. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Subwoofer Amplifier > Page 6227 Amplifier: Service and Repair Audio Amplifier Audio Amplifier Removal and Installation 1. Disconnect the audio amplifier electrical connectors. 2. NOTE: Move the passenger seat all the way back to access. Remove the 2 nuts, the bolt, and the audio amplifier. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Locations > Page 6231 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Locations > Page 6232 Radio/Stereo: Service and Repair Satellite Digital Audio Receiver System (SDARS) Module Removal and Installation NOTE: This procedure applies to vehicles without navigation only. For vehicle with navigation, the satellite radio receiver is built-in to the Audio Control Module (ACM). 1. NOTE: Module configuration is only required if a new Satellite Digital Audio Receiver System (SDARS) module is being installed. Upload the SDARS module configuration information to the scan tool. 2. Disconnect the SDARS module antenna cable and electrical connectors. 3. NOTE: Move the passenger seat all the way back to access. Remove the 2 nuts, the bolt, and the SDARS module. 4. To install, reverse the removal procedure. - Download the configuration information to the SDARS module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Service and Repair Remote Control: Service and Repair Steering Wheel Controls Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Service and Repair > Page 6236 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front > Page 6241 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front > Page 6242 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front > Page 6243 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker Speaker: Service and Repair Door Speaker Door Speaker NOTE: Front door shown, rear door similar. Removal and Installation 1. Remove the door trim panel. 2. Remove the 4 screws and the door speaker. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker > Page 6246 Speaker: Service and Repair Subwoofer Speaker Subwoofer Speaker Removal and Installation NOTE: The subwoofer speaker, amplifier, and enclosure and only replaced as a complete assembly. 1. Remove the RH quarter trim panel. 2. Disconnect the subwoofer amplifier electrical connector. 3. Remove the 3 bolts and the subwoofer speaker. - To install, tighten to 8 Nm (71 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6264 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6265 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6270 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6271 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: All Technical Service Bulletins SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6281 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6282 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6287 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6288 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) > Page 6291 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) Communications Control Module: Diagrams Accessory Protocol Interface Module (APIM) Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6294 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6295 Communications Control Module: Diagrams Audio Control Module (ACM) Part 1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6296 Part 2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6297 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures Communications Control Module: Procedures Accessory Protocol Interface Module (APIM) Software Level Check Accessory Protocol Interface Module (APIM) Software Level Check NOTE: This procedure applies to checking the Accessory Protocol Interface Module (APIM) software level. To program the APIM, refer to Accessory Protocol Interface Module (APIM) Programming in Information Bus. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning/Accessory Protocol Interface Module (APIM) Programming 1. Turn the Audio Control Module (ACM) on. 2. Connect the scan tool to the Data Link Connector (DLC). 3. Connect one end of the Universal Serial Bus (USB) male-A to male-A cable to the scan tool. 4. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 5. From the technician service publication website, run On-Line Automotive Service Information System (OASIS) using Quick Start or by manually entering the Vehicle Identification Number (VIN). 6. From the OASIS tab, select the "Sync/APIM" bullet. 7. Select the "Read APIM" button to verify the current Accessory Protocol Interface Module (APIM) software level. - The display shows both the Vehicle Interface Processor (VIP) and Consumer Interface Processor (CIP) software levels. 8. The scan tool displays the following information: - Last Recorded State - Hardware VIN: vehicle identification number associated with the current APIM - Installed date: date the APIM was installed - Radio: currently identified ACM in the vehicle - HW Part No.: APIM hardware part number - Un-installed date: date (if any) the APIM was uninstalled - S/N: APIM serial number - Last Recorded State - Software Date/Time: date and time of last recorded software installation - VIP: VIP software that was installed at that time - CIP: CIP software that was installed at that time Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6300 - Description: a description of the content of the software revision - History - Software Date/Time: date and time of any recorded software installation - VIP: VIP software that was installed at that time - CIP: CIP software that was installed at that time - Description: a description of the content of the software revision - Available Software for Programming Select: allows the software package to be selected - Lineage: the original software release, if the software available is a revision - VIP: VIP software level that is available with the selection - CIP: CIP software level that is available with the selection - Description: a description of the content of the software revision 9. Click a CIP software level to view the device compatibility list associated with the CIP software level, if desired. 10. To exit the APIM software level check, disconnect the scan tool from the DLC and the USB port, or exit the OASIS screen. Audio Control Module (ACM) Self-Diagnostic Mode Audio Control Module (ACM) Self-Diagnostic Mode Audio Systems Without Navigation 1. Turn the Audio Control Module (ACM) on. 2. Operate the audio system in radio tuner (AM/FM) mode. 3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins. - The display indicates each speaker as it is tested. 4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after step 3 by turning the ACM off. Before the speaker walk test is complete, carry out any of the following actions: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6301 5. To exit the self-diagnostic mode, turn the ACM off. Satellite Digital Audio Receiver System (SDARS) Module Electronic Serial Number (ESN) Retrieval - Vehicles Without Navigation 1. Operate the audio system in satellite radio mode. 2. Press and hold the AUX button and preset button 1, simultaneously. - The Satellite Digital Audio Receiver System (SDARS) module Electronic Serial Number (ESN) displays on the screen. 3. Record the SDARS module ESN. 4. Turn the audio system off. Navigation Audio System 1. Turn the Audio Control Module (ACM) on. 2. Operate the audio system in radio tuner (AM/FM) mode. 3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins. - The display indicates each speaker as it is tested. 4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after this step, or by allowing the speaker walk test to complete on its own. Before the speaker walk test is complete, press the "End Test" selection. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6302 5. The following tests are available through the "BEZEL DIAGNOSTICS" menu: 6. To exit the self-diagnostic mode, press the "Exit Diagnostics" selection from the "BEZEL DIAGNOSTICS" menu. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6303 Communications Control Module: Removal and Replacement Audio Control Module (ACM) Audio Control Module (ACM) All Except Navigation Navigation Removal and Installation All vehicles 1. NOTE: Module configuration is only required if a new ACM is being installed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6304 Upload the ACM configuration to the scan tool. 2. Remove the middle instrument panel center finish panel. 3. Remove the 4 ACM screws. - To install, tighten to 2 Nm (18 lb-in) (navigation). - To install, tighten to 1 Nm (9 lb-in) (all except navigation). Navigation 4. Disconnect the antenna and electrical connectors. All except navigation 5. If equipped, remove the 4 screws and the ACM side support brackets. 6. NOTE: Only carry out this step if installing a new ACM. Remove the 2 ACM brackets. All vehicles 7. Remove the ACM. 8. To install, reverse the removal procedure. - Download the configuration information to the ACM. Accessory Protocol Interface Module (APIM) Accessory Protocol Interface Module (APIM) Removal and Installation 1. NOTE: It is necessary to record the current Accessory Protocol Interface Module (APIM) software and hardware level when a new APIM is being installed to make sure that the new component is the same version as the component being replaced. Retrieve and record the current APIM software and hardware level. For additional information, refer to Accessory Protocol Interface Module (APIM) Software Level Check See: Procedures/Accessory Protocol Interface Module (APIM) Software Level Check. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6305 2. Remove the floor console. 3. Disconnect the APIM electrical connector and the Universal Serial Bus (USB) cable electrical connector. 4. Remove the 3 screws and the APIM. - Slide the APIM upward to release the locator clips. 5. To install, reverse the removal procedure. - If a new APIM is being installed, program the APIM to the correct software level. Universal Serial Bus (USB) Cable and Port Universal Serial Bus (USB) Cable and Port Floor Console Trim Panels Universal Serial Bus (USB) Port and Cable Removal and Installation Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6306 NOTE: The original equipment Universal Serial Bus (USB) port and cable is part of the wiring harness. It can only be serviced by overlaying a new USB port and cable. 1. Remove the transmission selector level bezel by pulling straight up. 2. NOTE: Open the floor console storage bin door. Remove the floor console finish panel by pulling straight up. - Disconnect the electrical connector, if necessary. 3. Remove the center instrument panel lower panel by pulling straight back. - Disconnect the electrical connectors. 4. Remove the USB cable and port. - Disconnect the cable from the Accessory Protocol Interface Module (APIM). - Cut the USB port and cable ends and secure them to prevent NVH concerns. 5. To install, reverse the removal procedure. - Secure the new USB port and cable, as necessary, to prevent NVH concerns. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6315 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6316 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6321 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6322 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6323 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6324 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6325 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6326 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6327 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6328 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6329 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6330 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6331 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6337 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6338 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6343 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6344 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6345 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6346 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6347 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6348 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6349 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6350 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6351 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6352 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6353 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 6358 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 6359 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 6365 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 6366 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > Customer Interest for Entertainment System Control Module: > 09-11-9 > Jun > 09 > Navigation Radio - Time Displays Twice In CD Mode Entertainment System Control Module: Customer Interest Navigation Radio - Time Displays Twice In CD Mode TSB 09-11-9 06/15/09 NAVIGATION RADIO - WHEN ON IN CD MODE - TIME DISPLAYS TWICE IN THE FDIM FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape and Mariner vehicles equipped with Navigation radio, may exhibit a concern when turning on the audio unit in CD mode. The time will display twice in the Front Display lnter[ace Module (FDIM), both in the center and in the upper right hand corner. Normal operation should be the time displaying in the center of the FDIM when the Navigation unit is off and in the upper right hand corner of the FDIM when the Navigation unit is on. ACTION Reprogram the Front Display Interface Module (FDIM) module to the latest calibration using IDS release 61.04 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration and IDS patch files may also be obtained at the website. 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 091109A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Reprogram The FDIM (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 19C116 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Entertainment System Control Module: > 09-11-9 > Jun > 09 > Navigation Radio - Time Displays Twice In CD Mode Entertainment System Control Module: All Technical Service Bulletins Navigation Radio - Time Displays Twice In CD Mode TSB 09-11-9 06/15/09 NAVIGATION RADIO - WHEN ON IN CD MODE - TIME DISPLAYS TWICE IN THE FDIM FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape and Mariner vehicles equipped with Navigation radio, may exhibit a concern when turning on the audio unit in CD mode. The time will display twice in the Front Display lnter[ace Module (FDIM), both in the center and in the upper right hand corner. Normal operation should be the time displaying in the center of the FDIM when the Navigation unit is off and in the upper right hand corner of the FDIM when the Navigation unit is on. ACTION Reprogram the Front Display Interface Module (FDIM) module to the latest calibration using IDS release 61.04 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration and IDS patch files may also be obtained at the website. 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 091109A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Reprogram The FDIM (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 19C116 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6388 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6389 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6395 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6396 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6405 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6406 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6412 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6413 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6417 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6418 Parking Assist Control Module: Service and Repair Parking Aid Module (PAM) Removal and Installation 1. NOTE: Module configuration is only required if a new Parking Aid Module (PAM) is being installed. Upload the PAM configuration information to the scan tool. 2. Remove the RH rear quarter trim panel. 3. If replacing the parking aid speaker only, proceed as follows: - Disconnect the electrical connector. - Disengage the clips. - Remove the parking aid speaker. 4. If replacing the PAM, proceed as follows: - Disconnect the electrical connector. - Remove the 2 screws. - Remove the PAM. 5. To install, reverse the removal procedure. - Download the configuration information to the PAM. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6424 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6425 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6426 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 6429 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 6430 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 6431 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 6432 Parking Assist Distance Sensor: Service and Repair Parking Aid Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The rear bumper cover removal is only necessary for access to the outer parking aid sensors. The inner parking aid sensors do not require rear bumper cover removal for access. Remove the rear bumper cover. 3. Press the retaining tabs and remove the parking aid sensor(s). - Disconnect the electrical connectors. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations > Page 6436 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations > Page 6437 Parking Assist Switch: Service and Repair Parking Aid Switch Removal and Installation 1. Remove the lower instrument panel center finish panel. 2. Press the retaining tabs and remove the parking aid switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams > Page 6441 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Brake Booster Travel Sensor - Hybrid Removal and Installation 1. Disconnect the brake booster travel sensor electrical connector. 2. Release the brake booster travel sensor retainer ring and remove the travel sensor. 3. To install, reverse the removal procedure. 4. Following the scan tool instructions, carry out the multi-calibration routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > A/T - Vehicle Flat Towing Guidelines Towing Information: Technical Service Bulletins A/T - Vehicle Flat Towing Guidelines TSB 09-20-13 10/19/09 6F35 TRANSMISSION - RECREATIONAL TOWING - VEHICLE WITH ALL 4 WHEELS ON THE GROUND - EXPANDED GUIDELINES TO PREVENT TRANSMISSION DAMAGE FORD: 2010 Fusion 2009-2010 Escape MERCURY: 2010 Milan 2009-2010 Mariner ISSUE Some 2009-2010 Escape, Mariner, 2010 Fusion and Milan vehicles equipped with a 6F35 automatic transmission, may experience transmission shift concerns after towing the vehicle with all 4 wheels on the ground (Flat tow) such as behind a motor home or a truck. The transmission shift concern may be caused by heat build up in the transmission due to the transmission fluid level being too high, towing speeds above 65 MPH (105 Km/h) and/or not stopping to run the engine at idle for 5 minutes every six hours or less, to cool the transmission. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE There are specific instructions listed in the Owner Guide that must be followed to recreational tow/flat tow/tow a vehicle with all 4 tires on the ground. Advise customers of the following expanded recreational towing guidelines. 1. Transmission fluid level must be checked at operating temperature of 185 °F - 200 °F (85 °C - 93 °C), per Workshop Manual (WSM), Section 307-01. At this temperature, adjust fluid level between minimum line and the minimum hole at the bottom of the hash marks on dipstick. This level is within the safe operating fluid level and does not require the customer to have the fluid level readjusted after flat tow operation. (Figure 1) 2. Maximum towing speed is 65 MPH (105 Km/h). 3. Do not flat tow the vehicle for greater than 6 hours at a time. 4. Start and run the engine for: a. 5 minutes before towing each day b. 5 minutes every 6 hours or less. c. While running the engine at idle for 5 minutes, with foot on the brake, shift through all gears. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > A/T - Vehicle Flat Towing Guidelines > Page 6447 These guidelines are designed to prevent damage to the transmission due to overheating. If setting the fluid level for a customer that will be recreational (flat) towing the vehicle, set the level between minimum line and the minimum hole at the bottom of the hash marks on dipstick (Figure 1) per WSM Section 307-01. NOTE THERE IS A SIGNIFICANT DIFFERENCE IN TRANSMISSION DIPSTICK READINGS BETWEEN A COLD TRANSMISSION AND A TRANSMISSION AT OPERATING TEMPERATURE. FAILURE TO CHECK TRANS FLUID LEVEL AT TRANS OPERATING TEMPERATURE, PER WSM SECTION 307-01 MAY RESULT IN DAMAGE TO THE TRANSMISSION. If the vehicle is a 2009 Escape or Mariner and built on or before 10/28/2008 the dipstick does not have Minimum - Maximum lines outside of hash marks, then replace dipstick. 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 MT092013 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 7000 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Special Tools Used With Diagnostics Trailer Lamps Principles of Operation Trailer Lamps Principles of Operation The trailer lamps are supplied power by the trailer tow park lamp relay, the LH trailer tow stop/turn relay and the RH trailer tow stop/turn relay. They are energized to correspond with the exterior lighting functions of the vehicle. A common ground is provided to the trailer tow connector for the trailer lamps. Inspection and Verification Trailer Lamps Inspection and Verification 1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. 3. Visually inspect for obvious signs of electrical damage. Visual Inspection Chart 4. If the concern is not visually evident, verify the symptom. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6452 Trailer Lamps: Symptom Related Diagnostic Procedures Trailer Lamps Symptom Chart Symptom Chart Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6453 Trailer Lamps: Pinpoint Tests Pinpoint Test Y: The Trailer Lamps Are Inoperative - All Trailer Lamps Pinpoint Tests Pinpoint Test Y: The Trailer Lamps Are Inoperative - All Refer to Wiring Diagram Set 95 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The trailer tow connector receives ground through circuits RAT08 (WH) and GD149 (BK/GY) for all of the trailer lamps. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE - ALL NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- Y1 CHECK CIRCUITS RAT08 (WH) AND GD149 (BK/GY) FOR AN OPEN - Disconnect: Trailer Tow C439. - Disconnect: Negative Battery Cable. - Measure the resistance between the trailer tow C439-4, circuit RAT08 (WH), harness side and ground. - Is the resistance less than 5 ohms? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No REPAIR circuit RAT08 (WH) or circuit GD149 (BK/GY) for an open. TEST the system for normal operation. ------------------------------------------------Pinpoint Test Z: The Individual Trailer Lamp Is Inoperative - Trailer Stop/Turn Lamp Trailer Lamps Pinpoint Tests Pinpoint Test Z: The Individual Trailer Lamp Is Inoperative - Trailer Stop/Turn Lamp Refer to Wiring Diagram Set 95 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Battery Junction Box (BJB) fuse 14 (15A) supplies voltage to the LH and RH trailer tow stop/turn relays. The trailer tow stop/turn relay coils are Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6454 grounded through circuit GD120 (BK/GN). The trailer tow LH stop/turn relay coil receives voltage from circuit CLS18 (GY/BN) when the vehicle LH rear stoplamp is illuminated. When the trailer tow LH stop/turn relay is energized, voltage is routed to the trailer tow connector through circuit CAT06 (YE). The trailer tow RH stop/turn relay coil receives voltage through circuit CLS19 (VT/OG) when the vehicle RH rear stoplamp is illuminated. When the trailer tow RH stop/turn relay is energized, voltage is routed to the trailer tow connector through circuit CAT09 (GN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow stop/turn relay - Trailer PINPOINT TEST Z: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - TRAILER STOP/TURN LAMP NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- Z1 CHECK CIRCUIT CAT06 (YE) OR CIRCUIT CAT09 (GN) FOR VOLTAGE - Ignition OFF. - Disconnect: Trailer Tow C439. - For the LH trailer stop/turn lamp, while applying the brake pedal, measure the voltage between the trailer tow C439-2, circuit CAT06 (YE), harness side and ground. - For the RH trailer stop/turn lamp, while applying the brake pedal, measure the voltage between the trailer tow C439-1, circuit CAT09 (GN), harness side and ground. - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No GO to Z2. ------------------------------------------------- Z2 CHECK THE TRAILER TOW STOP/TURN RELAY - Disconnect: Suspect Trailer Tow Stop/Turn Relay. - Substitute a know good relay. - For the LH trailer stop/turn lamp, while applying the brake pedal, measure the voltage between the trailer tow C439-2, circuit CAT06 (YE), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6455 - For the RH trailer stop/turn lamp, while applying the brake pedal, measure the voltage between the trailer tow C439-1, circuit CAT09 (GN), harness side and ground. - Is the voltage greater than 10 volts? Yes REMOVE the known good relay. INSTALL a new trailer tow stop/turn relay. TEST the system for normal operation. No REMOVE the known good relay. GO to Z3. ------------------------------------------------- Z3 CHECK CIRCUIT CLS18 (GY/BN) OR CIRCUIT CLS19 (VT/OG) FOR AN OPEN - While applying the brake pedal, measure the voltage between the trailer tow LH stop/turn relay pin 2, circuit CLS18 (GY/BN), BJB face side and ground; or between the trailer tow RH stop/turn relay pin 2, circuit CLS19 (VT/OG), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to Z4. No REPAIR the circuit in question for an open. TEST the system for normal operation. ------------------------------------------------- Z4 CHECK CIRCUIT SBB14 (BN/RD) FOR AN OPEN - Measure the voltage between the trailer tow LH stop/turn relay pin 3, circuit SBB14 (BN/RD), BJB face side and ground; or between the trailer tow RH stop/turn relay pin 3, circuit SBB14 (BN/RD), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to Z5. No Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6456 VERIFY the BJB fuse 14 (15A) is OK. If OK, REPAIR circuit SBB14 (BN/RD) for an open. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- Z5 CHECK CIRCUIT GD120 (BK/GN) FOR AN OPEN - Disconnect: Negative Battery Cable. - Measure the resistance between the trailer tow LH turn relay pin 1, circuit GD120 (BK/GN), BJB face side and ground; or between the trailer tow RH turn relay pin 1, circuit GD120 (BK/GN), BJB face side and ground. - Is the resistance less than 5 ohms? Yes REPAIR circuit CAT06 (YE) (LH trailer stop/turn) or circuit CAT09 (GN) (RH trailer stop/turn) for an open. TEST the system for normal operation. No REPAIR circuit GD120 (BK/GN) for an open. TEST the system for normal operation. ------------------------------------------------Pinpoint Test AA: The Trailer Lamps Are Inoperative - Trailer Parking Lamps Trailer Lamps Pinpoint Tests Pinpoint Test AA: The Trailer Lamps Are Inoperative - Trailer Parking Lamps Refer to Wiring Diagram Set 95 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The trailer tow parking lamp relay coil receives voltage through circuit CLS30 (VT/WH) when the vehicle parking lamps are illuminated. The trailer tow parking lamp relay coil is grounded through circuit GD120 (BK/GN). The Battery Junction Box (BJB) fuse 8 (20A) supplies voltage to the trailer tow parking lamp relay switch side. When the trailer tow parking lamp relay is energized, the voltage is routed to the trailer tow connector through circuit CAT11 (BN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow parking lamp relay - Trailer PINPOINT TEST AA: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER PARKING LAMPS NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- AA1 CHECK CIRCUIT CAT11 (BN) FOR VOLTAGE - Ignition OFF. - Disconnect: Trailer Tow C439. - Place the headlamp switch in the PARKING LAMPS ON position. - Measure the voltage between the trailer tow C439-3, circuit CAT11 (BN), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6457 - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No GO to AA2. ------------------------------------------------- AA2 CHECK THE TRAILER TOW PARKING LAMP RELAY - Place the headlamp switch in the OFF position. - Disconnect: Trailer Tow Parking Lamp Relay. - Substitute a known good relay. - Measure the voltage between the trailer tow C439-3, circuit CAT11 (BN), harness side and ground. - Is the voltage greater than 10 volts? Yes REMOVE the known good relay. INSTALL a new trailer tow parking lamp relay. TEST the system for normal operation. No REMOVE the known good relay. GO to AA3. ------------------------------------------------- AA3 CHECK CIRCUIT CLS30 (VT/WH) FOR AN OPEN - Place the headlamp switch in the PARKING LAMPS ON position. - Measure the voltage between the trailer tow parking lamp relay pin 2, circuit CLS30 (VT/WH), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to AA4. No REPAIR circuit CLS30 (VT/WH) for an open. TEST the system for normal operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6458 ------------------------------------------------- AA4 CHECK THE SBB08 (VT/RD) FOR AN OPEN - Place the headlamp switch in the OFF position. - Measure the voltage between the trailer tow parking lamp relay pin 3, circuit SBB08 (VT/RD), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to AA5. No VERIFY the BJB fuse 8 (20A) is OK. If OK, REPAIR circuit SBB08 (VT/RD) for an open. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- AA5 CHECK CIRCUIT GD120 (BK/GN) FOR AN OPEN - Disconnect: Negative Battery Cable. - Measure the resistance between the trailer tow parking lamp relay pin 1, circuit GD120 (BK/GN), BJB face side and ground. - Is the resistance less than 5 ohms? Yes REPAIR circuit CAT11 (BN) for an open. TEST the system for normal operation. No REPAIR circuit GD120 (BK/GN) for an open. TEST the system for normal operation. ------------------------------------------------Pinpoint Test AB: The Trailer Lamps Are On Continuously Trailer Lamps Pinpoint Tests Pinpoint Test AB: The Trailer Lamps Are On Continuously Refer to Wiring Diagram Set 95 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation - Trailer Tow Turn/Stoplamp Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6459 The trailer tow LH stop/turn relay coil receives voltage through circuit CLS18 (GY/BN) when the vehicle LH rear stoplamp is illuminated. When the trailer tow LH stop/turn relay is energized, voltage is routed to the trailer tow connector through circuit CAT06 (YE). The trailer tow RH stop/turn relay coil receives voltage through circuit CLS19 (VT/OG) when the vehicle RH rear stoplamp is illuminated. When the trailer tow RH stop/turn relay is energized, voltage is routed to the trailer tow connector through circuit CAT09 (GN). Trailer Tow Parking The trailer tow parking lamp relay coil receives voltage through circuit CLS30 (VT/WH) when the vehicle parking lamps are illuminated. When the trailer tow parking lamp relay is energized, voltage is routed to the trailer tow connector through circuit CAT11 (BN). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer tow relay - Trailer PINPOINT TEST AB: THE TRAILER LAMPS ARE ON CONTINUOUSLY ------------------------------------------------- AB1 CHECK FOR VOLTAGE AT THE TRAILER TOW CONNECTOR - Ignition OFF. - Disconnect: Trailer Tow C439. - Ignition ON. - Measure the voltage the between trailer tow connector, harness side and ground as follows: - Is any voltage present? Yes GO to AB2. No The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. ------------------------------------------------- AB2 CHECK THE SUSPECT RELAY - Ignition OFF. - Disconnect: Suspect Trailer Tow Relay. - Carry out the component test for the suspect trailer tow relay. - Is the trailer tow relay OK? Yes REPAIR circuit CAT06 (YE) (LH turn), circuit CAT09 (GN) (RH turn), or circuit CAT11 (BN) (parking lamps) for a short to voltage. TEST the system for normal operation. No Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6460 INSTALL a new turn trailer tow relay. TEST the system for normal operation. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Description and Operation Body Control Systems: Description and Operation Module Controlled Functions NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). NOTE: The time out for the battery saver relay and the accessory delay relay (both are controlled by the SJB) is 1 minute if the vehicle has less than 80 km (50 miles). Once the vehicle passes the approximate mileage threshold of 80 km (50 miles), the time out for both relays will be the normal 10 minute time out, as described by the Owner's Literature. For the accessory delay relay, refer to Windows. The SJB is the only multifunction electronic module on this vehicle. The SJB is a combination of a multifunction electronic module and a Central Junction Box (CJB). The following systems are controlled by the SJB: - Auto locks - Exterior lamps - Illuminated entry and interior lamps - Keyless entry keypad - Power door locks - Remote Keyless Entry (RKE) system - Tire Pressure Monitoring System (TPMS) The SJB is located under the front (passenger side floor) console. Post Crash Alert The post crash alert function is controlled by the SJB. If the Restraints Control Module (RCM) determines an impact of severity enough to deploy the air bags has occurred (the air bags may or may not be deployed by the RCM), the RCM sends a message to the Instrument Cluster (IC) over the High Speed Controller Area Network (HS-CAN), which sends a message to the SJB over the Medium Speed Controller Area Network (MS-CAN) and the SJB activates the post crash alert function by sounding the horn 3 times, then off for 4 seconds, then on 3 times, etc., until the battery dies or the function is turned off. The hazard lamps also flash with the horn sounding, however, the hazard lamps keep flashing during the horn off cycle. The post crash alert function can be turned off by: - pressing the hazard switch (may need to be pressed more than once). - pressing the Integrated Keyhead Transmitter (IKT) key UNLOCK button. - pressing the PANIC button. This feature acts similar to the perimeter alarm, but the horn cycle is different. Turning the ignition to the ON position will not deactivate this function, but will deactivate an activated perimeter alarm. The post crash alert function cannot be configured off. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview Body Control Systems: Initial Inspection and Diagnostic Overview Inspection And Verification Smart Junction Box (SJB) Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC). 5. NOTE: The Vehicle Communication Module (VCM) prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: - Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus, No Power To The Scan Tool, to diagnose no power to the scan tool. 6. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus to diagnose no response from the PCM. 7. Carry out the network test: - If the scan tool responds with no communication for one or more modules, refer to Information Bus. - If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the SJB. 9. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart. See: Diagnostic Trouble Code Descriptions/Smart Junction Box (SJB) DTC Chart See: Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart 10. If no DTCs related to the concern are retrieved, verify the symptom. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Principles Of Operation Smart Junction Box (SJB) Principles of Operation NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). NOTE: The time out for the battery saver relay and the accessory delay relay (both are controlled by the SJB) is 1 minute if the vehicle has less than 80 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6467 km (50 miles). Once the vehicle passes the approximate mileage threshold of 80 km (50 miles), the time out for both relays will be the normal 10 minute time out, as described by the Owner's Literature. For the accessory delay relay, refer to Windows. The SJB is a multifunction electronic module that controls many of the vehicle systems. Several SJB functions utilize hardwired inputs and/or outputs. The SJB controls the following hardwired functions, using the corresponding inputs and outputs: In addition, the SJB is involved in other vehicle systems through communication over the Controller Area Network (CAN). For a detailed list of the SJB network inputs and outputs, refer to Information Bus. Some SJB parameters are programmable. Two types of programmable parameters are available: vehicle configuration and customer preference. Refer to Information Bus for programmable parameters. Field-Effect Transistor (FET) Protection The SJB utilizes a Field-Effect Transistor (FET) protective circuit strategy for many of its outputs (for example, the headlamp output circuit). Output loads (current level) are monitored for excessive current (typically shorted circuits) and are shut down (turn off the voltage or ground provided by the module) when a fault is detected. A continuous DTC is stored at the time for the fault. The circuit resets after a customer demand (ignition cycle) of the function (which switches the component on, causing the 30-minute battery saver timer to be energized). When an excessive circuit load (from a shorted circuit) occurs several times, the module shuts down the output until a repair procedure is carried out. At the same time, the continuous DTC that was stored by the first failure does not clear by a command to clear the continuous DTCs. The SJB does not allow the DTC to be cleared or the normal circuit function restored until a successful self-test (retrieving on-demand DTCs) proves that the fault has been repaired. After the self-test has successfully completed (no on-demand DTCs present), the continuous DTC clear and the normal circuit function returns. The SJB has 3 predefined levels of short circuit tolerance established. When the first or second level is reached, the continuous DTC associated with the short circuit sets along with DTC B106E. These DTCs (B106E and the DTC associated with the shorted circuit) may be cleared using the Clear DTC operation on the scan tool as long as the fault itself has been corrected. Each and every time the scan tool retrieves DTCs from the module and a circuit is shorted, a level of short circuit tolerance is used up. If any of the circuits are shorted past the third level (if DTCs have been retrieved 3 successive times with the short circuit not having been repaired), then DTCs B106F and B1342 are set along with the associated continuous DTC. These DTCs (B106F and B1342) cannot be cleared and the module must be replaced. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6468 The initial short circuit must be successfully repaired and its associated DTC is cleared before the SJB is replaced or the new SJB may experience one or more of the short circuit tolerance levels being used up, causing a repeat replacement of the module. The SJB FET protected output circuits for the handles, locks, latches and entry systems are the liftgate lock actuator circuit CPL10 (GN/WH) and the keypad illumination circuit CPK28 (WH/GN). DTC B106E sets when the SJB has disabled a circuit due to a repetitive fault causing a circuit overload. A corresponding DTC for the circuit in question will also be set as follows: - DTC B1034 - Radio Start Signal Circuit Failure - DTC B1218 - Horn Relay Coil Circuit Short to Vbatt - DTC B1304 - Accessory Delay Relay Coil Circuit Short To Battery - DTC B1316 - Battery Saver Relay Coil Circuit Short To Ground - DTC B1349 - Heated Backlite Relay Short To Battery - DTC B1474 - Battery Saver Power Relay Circuit Short To Battery - DTC B1502 - Lamp Turn Signal Left Circuit Short To Ground - DTC B1506 - Lamp Turn Signal Right Circuit Short To Ground - DTC B1626 - Lamp Keypad Output Short Circuit To Ground - DTC B2070 - Trailer Tow Relay Coil(s) Circuit Failure - DTC B2501 - LF Lamp Low Beam Circuit Failure - DTC B2503 - RF Lamp Low Beam Circuit Failure - DTC B2505 - LF Lamp High Beam Circuit Failure - DTC B2507 - RF Lamp High Beam Circuit Failure - DTC B2512 - Front Fog Lamp Relay Ckt Short to Battery - DTC C1788 - Stoplamp Relay Output Circuit Short to Ground - DTC C1961 - Park Lamp Relay Coil Circuit Failure - DTC P0930 - Gear Shift Lock Solenoid Circuit Low Special Tools Used With Diagnostics Smart Junction Box (SJB) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6469 Body Control Systems: Diagnostic Trouble Code Descriptions Diagnostic Trouble Code (DTC) Chart Diagnostic Trouble Code (DTC) Chart NOTE: Most powertrain (P-code) DTCs are diagnosed in Computers and Control Systems Information. If the P-code retrieved is not listed below, refer to Computers and Control Systems Information to continue diagnostics. NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). NOTE: Some of these modules utilize a 5-character DTC followed by a 2-character failure-type code. The failure-type code provides information about specific fault conditions such as opens, or shorts to ground. Continuous memory DTCs have an additional 2-character DTC status code suffix to assist in determining DTC history. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6470 B0001:1A-B0011:13 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6471 B0011:2B-B0029:13 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6472 B0029:2B-B0092:11 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6473 B00A0:4A-B0097:96 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6474 B00B5:11-B1155 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6475 B11BA:1C-B1214:12 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6476 B12A0-B1299 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6477 B12AB-B1318 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6478 B1318-B1520 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6479 B1A01:01-B2032 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6480 B2044-B2427 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6481 B273A-B2870 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6482 B2A20-B2965 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6483 B2A2A-B2A4D / C0001:49-C0018:49 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6484 C001C:49-C0034:29 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6485 C003A:01-C0063:64 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6486 C0064:28-C1018:62 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6487 C101A:62-C1133:64 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6488 C1134:28-C1699 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6489 C1B00:28-C2780 / P0512-P0563 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6490 P0A0A-P0727 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6491 P0AA6-P2613 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6492 PXXXX-P2806 / U0001-U0131 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6493 U0131:87-U0155:00 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6494 U0155:00-U0256:00 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6495 U0256:00-U2014:41 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6496 U201A:51-U2100:56 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6497 U261A-U3003:17 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6498 U3003:17 Smart Junction Box (SJB) DTC Chart Smart Junction Box (SJB) DTC Charts B106E-B1342 / P062F / U0155-U2473 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6499 Body Control Systems: Symptom Related Diagnostic Procedures Smart Junction Box (SJB) Symptom Chart Symptom Chart Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6500 Body Control Systems: Pinpoint Tests Pinpoint Test A: DTCs B106E/B106F Smart Junction Box (SJB) Pinpoint Tests Pinpoint Test A: DTCs B106E/B106F Normal Operation When a repetitive fault causing a circuit overload is detected on certain output circuits, the Smart Junction Box (SJB) disables the circuit by removing voltage, or ground, to the affected circuit. The circuit remains disabled until the fault is corrected and an on-demand self-test is run. When the on-demand self-test has been run after all faults have been corrected, any DTCs related to the fault are cleared. - DTC B106E (Solid State Driver Disabled Due to Short Circuit) - sets when the SJB has disabled a circuit due to a repetitive fault causing a circuit overload. For a complete list of corresponding DTCs, refer to the Principles of Operation. See: Initial Inspection and Diagnostic Overview/Principles Of Operation - DTC B106F (Module Disabled Due to External Fault) - sets when one or more output functions are permanently disabled due to a repetitive circuit overload fault. When DTC B106F is present (DTC B1342 may also be present), the SJB must be replaced after the fault condition has been corrected. This pinpoint test is intended to diagnose the following: - Output circuit short to ground or voltage - SJB PINPOINT TEST A: DTCs B106E/B106F NOTICE: If DTC B106F is present and the Smart Junction Box (SJB) is to be replaced, the fault condition must be corrected first. Failure to correct the fault condition first may cause damage to the new SJB, resulting in a repeat repair. NOTICE: If DTC B106F is present, DTC B1342 may also be present. At this time, ignore these DTCs and follow the necessary diagnostics to resolve DTC B106E and any other DTCs that are present. DTC B106E will be present only when there is another DTC due to a software issue or a circuitry issue that must be resolved before another self-test is run. Each time a self-test is run, one of the 3 thresholds is used. Once the 3 thresholds are used, DTCs B106F and B1342 will be present and the SJB must be replaced. All other DTCs MUST be resolved first, or else the new SJB will begin to have its 3 thresholds used with each self-test that is run. ------------------------------------------------- A1 CHECK FOR DTC B106E - Review the DTCs from the SJB self-test. - Is DTC B106E present? Yes GO to A2. No GO to A3. ------------------------------------------------- A2 CHECK FOR OTHER DTCs - Review the DTCs from the SJB self-test. Are any SJB DTCs present other than DTC B106E? Yes CORRECT any other DTCs. REFER to the Diagnostic Trouble Code (DTC) Chart See: Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart. REPEAT the self-test (on-demand DTCs). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6501 No CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. ------------------------------------------------- A3 CHECK FOR DTC B106F - Review the DTCs from the SJB self-test. - Is DTC B106F present? Yes CORRECT any other DTCs. REFER to Diagnostic Trouble Code (DTC) Chart See: Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart. INSTALL a new SJB. REFER to Smart Junction Box (SJB) See: Power and Ground Distribution/Power Distribution Module/Service and Repair. TEST the system for normal operation. No The system is operating correctly at this time. The concern was caused by a fault in one of the output circuits. ------------------------------------------------Pinpoint Test B: DTC B1317 Smart Junction Box (SJB) Pinpoint Tests Pinpoint Test B: DTC B1317 Refer to Wiring Diagram Set 13 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Power Distribution/SJB for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Smart Junction Box (SJB) monitors the voltage from the battery to determine if it goes above or below specific thresholds and sets DTC B1317 in continuous memory and on-demand if the SJB detects high battery voltage above 15.5 volts on circuit SBB02 (YE/RD). - DTC B1317 (Battery Voltage High) - a continuous memory or on-demand DTC that sets when the SJB detects battery voltage above 15.5 volts on circuit SBB02 (YE/RD). This pinpoint test is intended to diagnose the following: - Charging system concern - SJB PINPOINT TEST B: DTC B1317 NOTE: DTC B1317 may be stored in the module memory due to previous battery charging or vehicle jump starting events. ------------------------------------------------- B1 CHECK FOR DTC B1317, B1676 OR P0563 SET IN OTHER MODULES - Ignition ON. - Enter the following diagnostic mode on the scan tool: (All CMDTCs) Self-Test. - Retrieve the continuous memory DTCs from all modules. Is DTC B1317, B1676 or P0563 (PCM) set in more than one module? Yes REFER to Charging System to diagnose an overcharging condition. No GO to B2. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6502 ------------------------------------------------- B2 CHECK THE BATTERY VOLTAGE - Turn off all interior/exterior lights and accessories. - Start and run the engine at approximately 2,000 rpm for 3 minutes while monitoring the battery voltage. - Does the battery voltage rise to 15.5 volts or higher? Yes REFER to Charging System to diagnose an overcharging condition. No GO to B3. ------------------------------------------------- B3 RECHECK FOR DTC B1317 - Turn the engine off. - Ignition ON. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the continuous memory DTCs. - Carry out the SJB self-test. - Is DTC B1317 present? Yes INSTALL a new SJB. REFER to Smart Junction Box (SJB) See: Power and Ground Distribution/Power Distribution Module/Service and Repair. TEST the system for normal operation. No The system is operating normally at this time. The DTC may have been set previously during battery charging or while jump starting the vehicle. ------------------------------------------------Pinpoint Test C: DTC B1318 Smart Junction Box (SJB) Pinpoint Tests Pinpoint Test C: DTC B1318 Refer to Wiring Diagram Set 13 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Power Distribution/SJB for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Smart Junction Box (SJB) monitors the voltage from the battery to determine if it goes above or below specific thresholds and sets DTC B1318 in continuous memory and on-demand if the SJB detects low battery voltage below 10 volts on circuit SBB02 (YE/RD). - DTC B1318 (Battery Voltage Low) - a continuous memory or on-demand DTC that sets when the SJB detects battery voltage below 10 volts on circuit SBB02 (YE/RD). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - High circuit resistance - SJB PINPOINT TEST C: DTC B1318 NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6503 NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- C1 RECHECK THE SJB DTCs - Ignition ON. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the DTCs. Repeat the SJB self-test. - Is DTC B1318 still present? Yes GO to C2. No The system is operating normally at this time. The DTC may have been set previously during battery charging or while jump starting the vehicle. ------------------------------------------------- C2 CHECK FOR CHARGING SYSTEM DTCs IN THE PCM - Enter the following diagnostic mode on the scan tool: PCM Self-Test. - Retrieve the continuous memory DTCs from the PCM. - Is DTC P0620, P0625, P0626 or P065B set in the PCM? Yes REFER to Charging System. No GO to C3. ------------------------------------------------- C3 CHECK THE BATTERY CONDITION AND STATE OF CHARGE - Ignition OFF. - Check the battery condition and verify the battery is fully charged. Refer to Battery, Battery Condition Test. See: Starting and Charging/Battery/Testing and Inspection/Pinpoint Tests - Is the battery OK and fully charged? Yes GO to C4. No REFER to Charging System. ------------------------------------------------- C4 CHECK THE SJB VOLTAGE SUPPLY - Measure and record the voltage at the battery. - Disconnect: SJB C2280G. - Ignition ON. - Measure the voltage between the SJB C2280G-1, circuit SBB02 (YE/RD), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6504 - Is the voltage within 0.2 volt of the recorded battery voltage? Yes GO to C5. No REPAIR the circuit for high resistance. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- C5 CHECK THE SJB GROUND CIRCUIT - Ignition OFF. - Disconnect: Negative Battery Cable. - Disconnect: SJB C2280D. - Measure the resistance between the SJB C2280D-7, 24, circuit GD182 (BK/GY), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to C6. No REPAIR the circuit for high resistance. TEST the system for normal operation. ------------------------------------------------- C6 CHECK FOR CORRECT SJB OPERATION - Connect: Negative Battery Cable. - Disconnect the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. REFER to Smart Junction Box (SJB) See: Power and Ground Distribution/Power Distribution Module/Service and Repair. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6505 ------------------------------------------------Pinpoint Test D: DTC U0155 Smart Junction Box (SJB) Pinpoint Test D: DTC U0155 Normal Operation - DTC U0155 (Lost Communication with Instrument Panel Cluster (IC) Control Module) - set by the Smart Junction Box (SJB) if data messages received from the Instrument Cluster (IC) over the Medium Speed Controller Area Network (MS-CAN) are missing for 5 minutes. This pinpoint test is intended to diagnose the following: - Module communication - IC PINPOINT TEST D: DTC U0155 ------------------------------------------------- D1 VERIFY CUSTOMER CONCERN - Ignition ON. - Verify that there is an observable symptom present. - Is an observable symptom present? Yes GO to D2. No The system is operating normally at this time. The DTC may have been set due to high network traffic or intermittent fault condition. ------------------------------------------------- D2 CHECK THE COMMUNICATION NETWORK - Ignition ON. - Enter the following diagnostic mode on the scan tool: Network Test. - Carry out the network test. - Does the IC pass the network test? Yes GO to D3. No REFER to Information Bus. ------------------------------------------------- D3 RETRIEVE THE RECORDED DTCs FROM THE SELF-TEST - Check for recorded SJB DTCs from the self-test. - Is DTC B1317 or B1318 recorded? Yes For DTC B1317, Go To Pinpoint Test b. See: Pinpoint Test B: DTC B1317 For DTC B1318, Go To Pinpoint Test c. See: Pinpoint Test C: DTC B1318 No GO to D4. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 6506 ------------------------------------------------- D4 RECHECK THE SJB DTCs NOTE: If new modules were installed prior to the DTC being set, the module configuration may be incorrectly set during Programmable Module Installation (PMI) or the PMI may not have been carried out. - Clear the DTCs. Repeat the SJB self-test. - Is DTC U0155 still present? Yes INSTALL a new IC. TEST the system for normal operation. REPEAT the SJB self-test. If DTC U0155 is still present, INSTALL a new SJB. No The system is operating correctly at this time. The DTC may have been set due to high network traffic or intermittent fault condition. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair Auxiliary Step / Running Board: Service and Repair Running Board Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Release the running board trim bezel push clips and remove the running board trim bezel. 3. Remove the 4 running board bolts and remove the running board. - To install, tighten to 25 Nm (18 lb-ft). 4. Remove the body-to-running board bracket screw. - To install, tighten to 10 Nm (89 lb-in). 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures Front Bumper Cover / Fascia: Procedures Tab Repair - Bumper 1. NOTE: Inspect the bumper cover to determine if part can be repaired to an acceptable level of quality of appearance, fit and durability. Will labor and material cost of the repair meet or exceed the cost of a new replacement bumper cover? If the bumper cover is determined to be repairable, proceed to the following steps. NOTE: The following steps are to be used as a guideline. Depending on what brand of adhesives or patch materials are used, procedures may vary slightly. Remove the affected bumper. 2. Clean the broken tab(s) with a plastics wax and grease remover. 3. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed air. 4. Apply a plastics adhesion promoter per label directions to the repair area. 5. Measure and cut a patch of fiberglass cloth or equivalent large enough to form the front of the tab, then slope back in a wedge shape approximately 51 mm (2 in) from original tab. 6. Prepare the repair adhesive cloth patch per manufacturer's instructions and apply to the affected area. - Immediately position the plastic repair material patch to form the tab shape. 7. Allow appropriate cure time and shape the repair tab using a small angle sander. Use extreme care to not sand through the exterior surface. 8. NOTICE: The High Voltage Traction Battery (HVTB) in a Hybrid Electric Vehicle (HEV) can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60°C (140°F). Therefore, during refinishing operations, the paint booth temperature must be set at or below 60°C (140°F) with a bake time of 45 minutes or less. Temperatures in excess of 60°C (140°F) or bake durations longer than 45 minutes will require the HVTB be removed from the vehicle prior to placing in the paint booth. For additional information, refer to Hybrid Drive Systems. Perform any required paint repair operations to the bumper cover using Ford-approved paint systems. 9. Reassemble and install the bumper cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 6516 Front Bumper Cover / Fascia: Removal and Replacement Bumper Cover - Front Removal and Installation NOTICE: Prior to removal of the front bumper cover, place tape at the corners of the bumper cover and below the headlamps to prevent damage to the paint. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 6 pushpins from inside the front splash shield (3 each side). 3. Remove the 4 fender splash shield-to-air deflector bolts (2 each side). - To install, tighten to 5 Nm (44 lb-in). 4. Remove the 3 air deflector bolts. - To install, tighten to 5 Nm (44 lb-in). 5. Remove the 2 front bumper cover center pushpins from the front bumper cover. 6. If equipped, disconnect the fog lamp electrical connectors. 7. If equipped, disconnect the front parking aid sensor harness. 8. Remove the 2 bolts that attach the grille to the radiator support bracket. - To install, tighten to 8 Nm (71 lb-in). 9. To install, reverse the removal procedure. - Position the front bumper cover. - Push inward on the sides of the bumper cover near the bottom corner of the headlamp until the bumper cover snap onto the bumper slides. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures Rear Bumper Cover / Fascia: Procedures Tab Repair - Bumper 1. NOTE: Inspect the bumper cover to determine if part can be repaired to an acceptable level of quality of appearance, fit and durability. Will labor and material cost of the repair meet or exceed the cost of a new replacement bumper cover? If the bumper cover is determined to be repairable, proceed to the following steps. NOTE: The following steps are to be used as a guideline. Depending on what brand of adhesives or patch materials are used, procedures may vary slightly. Remove the affected bumper. 2. Clean the broken tab(s) with a plastics wax and grease remover. 3. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed air. 4. Apply a plastics adhesion promoter per label directions to the repair area. 5. Measure and cut a patch of fiberglass cloth or equivalent large enough to form the front of the tab, then slope back in a wedge shape approximately 51 mm (2 in) from original tab. 6. Prepare the repair adhesive cloth patch per manufacturer's instructions and apply to the affected area. - Immediately position the plastic repair material patch to form the tab shape. 7. Allow appropriate cure time and shape the repair tab using a small angle sander. Use extreme care to not sand through the exterior surface. 8. NOTICE: The High Voltage Traction Battery (HVTB) in a Hybrid Electric Vehicle (HEV) can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60°C (140°F). Therefore, during refinishing operations, the paint booth temperature must be set at or below 60°C (140°F) with a bake time of 45 minutes or less. Temperatures in excess of 60°C (140°F) or bake durations longer than 45 minutes will require the HVTB be removed from the vehicle prior to placing in the paint booth. For additional information, refer to Hybrid Drive Systems. Perform any required paint repair operations to the bumper cover using Ford-approved paint systems. 9. Reassemble and install the bumper cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 6522 Rear Bumper Cover / Fascia: Removal and Replacement Bumper Cover - Rear Removal and Installation 1. Remove the 4 rear bumper cover center screws. 2. Remove the 2 rear splash shields. - Remove the 4 splash shield pin-type retainers (2 each side). - Remove the 4 splash shield screws (2 each side). - To install, tighten to 5 Nm (44 lb-in). 3. Remove the 2 rear bumper cover upper screws (1 each side). - To install, tighten to 5 Nm (44 lb-in). 4. Remove the 2 liftgate alignment bumper bolts and the 2 liftgate alignment bumpers. - To install, tighten to 8 Nm (71 lb-in). 5. If equipped, disconnect the parking aid system or trailer tow electrical connector. 6. Remove the rear bumper cover. 7. To install, reverse the removal procedure. - When installing, position the rear bumper cover into the bumper slides. - Transfer all necessary components. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 2 wiper pivot arms nuts. - To install, tighten to 35 Nm (26 lb-ft). 2. Remove the LH and RH wiper pivot arms. 3. Remove the LH and RH cowl end cap pushpin retainers. 4. Remove the cowl end caps. 5. Release the cowl panel grille from the retaining clips and remove the cowl panel grille. 6. To install, reverse the removal procedure. - Adjust the wiper pivot arms. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Exterior Handle: > 09-24-7 > Dec > 09 > Body - Exterior Door Handle(s) Hard T0 Open/Not Flush Front Door Exterior Handle: Customer Interest Body - Exterior Door Handle(s) Hard T0 Open/Not Flush TSB 09-24-7 12/14/09 EXTERIOR DOOR HANDLE DIFFICULT TO OPEN/HANDLE NOT SITTING FLUSH WHEN RELEASED/HANDLE STICKING WHEN OPENING DOOR - BUILT ON OR BEFORE 9/1/2009 FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 9/1/2009 may exhibit an exterior door handle that is difficult to open, does not sit flush when released, and/or sticks when opening door. This may be due to the exterior door handle plunger binding on the door handle bezel. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE 1. Remove the exterior door bezel on affected door(s) per Workshop Manual (WSM), Section 501-14. 2. Closely examine the exterior door bezel for signs of damage; inspect for a groove worn into the bezel due to contact with the door handle plunger. Is any damage present? (Figure 1) a. No - Do not continue with this procedure and follow WSM, Section 501-14 Symptom Chart pinpoint test T. b. Yes - Replace bezel with revised exterior door bezel as necessary following WSM, Section 501-14. Parts Block 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Exterior Handle: > 09-24-7 > Dec > 09 > Body - Exterior Door Handle(s) Hard T0 Open/Not Flush > Page 6539 092407A 2008-2010 Escape, 0.6 Hr. Mariner: Inspect And Replace One (1) Front Bezel. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407B 2008-2010 Escape, 1.0 Hr. Mariner: Inspect And Replace Two (2) Front Bezels. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407C 2008-2010 Escape, 0.5 Hr. Mariner: Inspect And Replace One (1) Rear Bezel. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) 092407D 2008-2010 Escape, 0.8 Hr. Mariner: Inspect And Replace Two (2) Rear Bezels. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) DEALER CODING CONDITION BASIC PART NO. CODE 7822404 30 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > 09-24-7 > Dec > 09 > Body - Exterior Door Handle(s) Hard T0 Open/Not Flush Front Door Exterior Handle: All Technical Service Bulletins Body - Exterior Door Handle(s) Hard T0 Open/Not Flush TSB 09-24-7 12/14/09 EXTERIOR DOOR HANDLE DIFFICULT TO OPEN/HANDLE NOT SITTING FLUSH WHEN RELEASED/HANDLE STICKING WHEN OPENING DOOR - BUILT ON OR BEFORE 9/1/2009 FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 9/1/2009 may exhibit an exterior door handle that is difficult to open, does not sit flush when released, and/or sticks when opening door. This may be due to the exterior door handle plunger binding on the door handle bezel. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE 1. Remove the exterior door bezel on affected door(s) per Workshop Manual (WSM), Section 501-14. 2. Closely examine the exterior door bezel for signs of damage; inspect for a groove worn into the bezel due to contact with the door handle plunger. Is any damage present? (Figure 1) a. No - Do not continue with this procedure and follow WSM, Section 501-14 Symptom Chart pinpoint test T. b. Yes - Replace bezel with revised exterior door bezel as necessary following WSM, Section 501-14. Parts Block 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > 09-24-7 > Dec > 09 > Body - Exterior Door Handle(s) Hard T0 Open/Not Flush > Page 6545 092407A 2008-2010 Escape, 0.6 Hr. Mariner: Inspect And Replace One (1) Front Bezel. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407B 2008-2010 Escape, 1.0 Hr. Mariner: Inspect And Replace Two (2) Front Bezels. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407C 2008-2010 Escape, 0.5 Hr. Mariner: Inspect And Replace One (1) Rear Bezel. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) 092407D 2008-2010 Escape, 0.8 Hr. Mariner: Inspect And Replace Two (2) Rear Bezels. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) DEALER CODING CONDITION BASIC PART NO. CODE 7822404 30 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > Page 6546 Front Door Exterior Handle: By Symptom Technical Service Bulletin # 09-24-7 Date: 091214 Body - Exterior Door Handle(s) Hard T0 Open/Not Flush TSB 09-24-7 12/14/09 EXTERIOR DOOR HANDLE DIFFICULT TO OPEN/HANDLE NOT SITTING FLUSH WHEN RELEASED/HANDLE STICKING WHEN OPENING DOOR - BUILT ON OR BEFORE 9/1/2009 FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 9/1/2009 may exhibit an exterior door handle that is difficult to open, does not sit flush when released, and/or sticks when opening door. This may be due to the exterior door handle plunger binding on the door handle bezel. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE 1. Remove the exterior door bezel on affected door(s) per Workshop Manual (WSM), Section 501-14. 2. Closely examine the exterior door bezel for signs of damage; inspect for a groove worn into the bezel due to contact with the door handle plunger. Is any damage present? (Figure 1) a. No - Do not continue with this procedure and follow WSM, Section 501-14 Symptom Chart pinpoint test T. b. Yes - Replace bezel with revised exterior door bezel as necessary following WSM, Section 501-14. Parts Block 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > Page 6547 OPERATION DESCRIPTION TIME 092407A 2008-2010 Escape, 0.6 Hr. Mariner: Inspect And Replace One (1) Front Bezel. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407B 2008-2010 Escape, 1.0 Hr. Mariner: Inspect And Replace Two (2) Front Bezels. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407C 2008-2010 Escape, 0.5 Hr. Mariner: Inspect And Replace One (1) Rear Bezel. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) 092407D 2008-2010 Escape, 0.8 Hr. Mariner: Inspect And Replace Two (2) Rear Bezels. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) DEALER CODING CONDITION BASIC PART NO. CODE 7822404 30 Disclaimer Technical Service Bulletin # 09-24-7 Date: 091214 Body - Exterior Door Handle(s) Hard T0 Open/Not Flush TSB 09-24-7 12/14/09 EXTERIOR DOOR HANDLE DIFFICULT TO OPEN/HANDLE NOT SITTING FLUSH WHEN RELEASED/HANDLE STICKING WHEN OPENING DOOR - BUILT ON OR BEFORE 9/1/2009 FORD: 2008-2010 Escape MERCURY: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > Page 6548 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 9/1/2009 may exhibit an exterior door handle that is difficult to open, does not sit flush when released, and/or sticks when opening door. This may be due to the exterior door handle plunger binding on the door handle bezel. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE 1. Remove the exterior door bezel on affected door(s) per Workshop Manual (WSM), Section 501-14. 2. Closely examine the exterior door bezel for signs of damage; inspect for a groove worn into the bezel due to contact with the door handle plunger. Is any damage present? (Figure 1) a. No - Do not continue with this procedure and follow WSM, Section 501-14 Symptom Chart pinpoint test T. b. Yes - Replace bezel with revised exterior door bezel as necessary following WSM, Section 501-14. Parts Block 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 092407A 2008-2010 Escape, 0.6 Hr. Mariner: Inspect And Replace One (1) Front Bezel. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407B 2008-2010 Escape, 1.0 Hr. Mariner: Inspect And Replace Two (2) Front Bezels. This Labor Operation Can Be Claimed With C Or D (If The New Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > Page 6549 Bezel Requires Paint Use B-Time) 092407C 2008-2010 Escape, 0.5 Hr. Mariner: Inspect And Replace One (1) Rear Bezel. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) 092407D 2008-2010 Escape, 0.8 Hr. Mariner: Inspect And Replace Two (2) Rear Bezels. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) DEALER CODING CONDITION BASIC PART NO. CODE 7822404 30 Disclaimer Technical Service Bulletin # 09-24-7 Date: 091214 Body - Exterior Door Handle(s) Hard T0 Open/Not Flush TSB 09-24-7 12/14/09 EXTERIOR DOOR HANDLE DIFFICULT TO OPEN/HANDLE NOT SITTING FLUSH WHEN RELEASED/HANDLE STICKING WHEN OPENING DOOR - BUILT ON OR BEFORE 9/1/2009 FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 9/1/2009 may exhibit an exterior door handle that is difficult to open, does not sit flush when released, and/or sticks when opening door. This may be due to the exterior door handle plunger binding on the door handle bezel. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE 1. Remove the exterior door bezel on affected door(s) per Workshop Manual (WSM), Section 501-14. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > Page 6550 2. Closely examine the exterior door bezel for signs of damage; inspect for a groove worn into the bezel due to contact with the door handle plunger. Is any damage present? (Figure 1) a. No - Do not continue with this procedure and follow WSM, Section 501-14 Symptom Chart pinpoint test T. b. Yes - Replace bezel with revised exterior door bezel as necessary following WSM, Section 501-14. Parts Block 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 092407A 2008-2010 Escape, 0.6 Hr. Mariner: Inspect And Replace One (1) Front Bezel. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407B 2008-2010 Escape, 1.0 Hr. Mariner: Inspect And Replace Two (2) Front Bezels. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407C 2008-2010 Escape, 0.5 Hr. Mariner: Inspect And Replace One (1) Rear Bezel. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) 092407D 2008-2010 Escape, 0.8 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > Page 6551 Mariner: Inspect And Replace Two (2) Rear Bezels. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) DEALER CODING CONDITION BASIC PART NO. CODE 7822404 30 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 > Door Handle Reinforcement - Exterior, Front Front Door Exterior Handle: Service and Repair Door Handle Reinforcement - Exterior, Front Door Handle Reinforcement - Exterior, Front Removal and Installation NOTE: The door glass must be completely raised. 1. Remove the exterior front door handle. For additional information, refer to Exterior Front Door Handle See: Exterior Front Door Handle. 2. Disconnect the door latch carrier. 1. Release the retainer and position the door latch carrier aside. 2. Remove the exterior front door handle reinforcement screw. 3. Disconnect the actuating rods. - If necessary, disconnect the lock cylinder actuating rod from the exterior front door handle reinforcement. - Disconnect the exterior front door handle reinforcement actuating rod from the front door latch. 4. Remove the exterior front door handle reinforcement with the exterior front door handle reinforcement actuating rod. 5. If necessary, remove the exterior front door handle reinforcement actuating rod. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 > Door Handle Reinforcement - Exterior, Front > Page 6554 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 > Door Handle Reinforcement - Exterior, Front > Page 6555 Front Door Exterior Handle: Service and Repair Exterior Front Door Handle Exterior Front Door Handle Removal and Installation 1. Remove the front door trim panel. 2. Position the watershield aside. 3. Remove the exterior front door handle cover retaining screw from the door handle reinforcement. 4. Remove the exterior front door handle bezel. 1. Pull the exterior front door handle open. 2. Pivot the rear of the exterior front door handle bezel and remove. 5. Remove the exterior front door handle. - Open and pull the exterior front door handle rearward to release and remove. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 > Door Handle Reinforcement - Exterior, Front > Page 6556 6. If necessary, remove the exterior front door handle seals. 7. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 > Door Handle Reinforcement - Exterior, Front > Page 6557 Front Door Exterior Handle: Service and Repair Front Door Handles, Locks and Latches Exploded View Front Door Handles, Locks and Latches - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Handles, Locks and Latches - Exploded View Front Door Interior Handle: Service and Repair Front Door Handles, Locks and Latches - Exploded View Front Door Handles, Locks and Latches - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Handles, Locks and Latches - Exploded View > Page 6562 Front Door Interior Handle: Service and Repair Interior Door Handle - Front Interior Door Handle - Front Removal and Installation 1. Remove the front door trim panel. 2. Release the interior front door handle retaining tabs and remove the interior front door handle. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments Front Door Hinge: Adjustments Door Alignment - Front All alignments NOTE: Driver side shown, passenger side similar. 1. Remove the door latch striker plate. Front door in and out, up and down alignment 2. Loosen, but do not remove, the front door hinge-to-front door fasteners enough to allow door alignment. Front door fore, aft and tilt alignment 3. Remove the front fender. 4. Loosen, but do not remove, the upper front door hinge-to-body fasteners enough to allow door alignment. 5. Remove the front door scuff plate. 6. Partially remove the front door weatherstrip. 7. Remove the lower cowl trim panel. - Remove the pin-type retainer. - Remove the lower cowl trim panel. 8. Remove the front door hinge-to-body bolts inside at the inside A-pillar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Page 6566 9. Position the weather shield aside and loosen, but do not remove, the front door lower hinge nut. 10. Loosen, but do not remove, the lower front door hinge-to-body fasteners enough to allow door alignment. All alignments 11. Adjust the door. 12. Tighten the door fasteners. - Tighten the front door hinge-to-front door fasteners to 24 Nm (18 lb-ft). - Tighten the front door hinge-to-body fasteners to 24 Nm (18 lb-ft). 13. Install and adjust the door striker as necessary. - Tighten the door latch striker plate bolts to 30 Nm (22 lb-ft). 14. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge - Upper, Front Front Door Hinge: Service and Repair Door Hinge - Upper, Front Door Hinge - Upper, Front 1. Remove the front door. For additional information, refer to Door See: Service and Repair. 2. Remove the instrument panel. 3. Remove the hinge-to-body bolts and remove the hinge. - To install, tighten to 24 Nm (18 lb-ft). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge - Upper, Front > Page 6569 Front Door Hinge: Service and Repair Door Hinge - Lower, Front Door Hinge - Lower, Front 1. Remove the front door. For additional information, refer to Door See: Service and Repair. 2. Remove the scuff plate trim panel pin-type retainers. 3. Remove the scuff plate trim panel. 4. Pull outward to release the cowl trim panel clips and remove the cowl trim panel. 5. Remove the hinge-to-body bolts and remove the hinge. - To install, tighten to 24 Nm (18 lb-ft). 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Procedures Front Door Latch: Procedures Latch Lubrication 1. Open the door. 2. Using a screwdriver, fully close the latch (two clicks). 3. Spray the multi-purpose grease into the opening on the door latch for approximately 5 seconds. 4. Open the latch using either the interior or exterior door handle. 5. Open and close the door several times to circulate the lubricant inside the latch. 6. Wipe off any excess grease. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Procedures > Page 6574 Front Door Latch: Removal and Replacement Front Door Handles, Locks and Latches - Exploded View Front Door Handles, Locks and Latches - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Procedures > Page 6575 Front Door Latch Front Door Latch Removal and Installation NOTE: The door glass must be completely raised. 1. Remove the front door trim panel. 2. Position the water shield aside. 3. Remove the exterior front door handle reinforcement. For additional information, refer to Door Handle Reinforcement - Exterior, Front See: Front Door Handle/Front Door Exterior Handle/Service and Repair/Door Handle Reinforcement - Exterior, Front. 4. Remove and discard the 3 front door latch bolts. - To install, tighten to 12 Nm (106 lb-in). 5. Disconnect the front door latch electrical connector. 6. Remove the front door latch. - Slide the front door latch towards the front of the vehicle. - Remove the front door latch with the door lock actuating rod and the interior door handle actuating cable. 7. If necessary, remove the door lock actuating rod and the interior door handle actuating cable. 8. To install, reverse the removal procedure. - Lubricate the front door latch to striker surfaces after installation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Door Trim Panel - Front NOTE: Escape shown, Mariner similar. Removal and Installation NOTE: LH side shown, RH side similar. 1. Remove the door sail panel. - If equipped, disconnect the power mirror electrical connector. 2. Open and remove the door handle finish panel. - Pull the door handle outward to fully access the door handle finish panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 6579 3. Remove the door handle screw. 4. Remove the door pull cup screw cover. 5. Remove the door pull cup screw. 6. Remove the 3 door trim panel screws. 7. Remove the door trim panel. - Pull outward and then upward on the door trim panel. - Disconnect the electrical connectors. 8. Remove the door handle from the door trim panel. - Disconnect the electrical connector. - Press the 2 retaining tabs while pushing the door handle from the door trim panel. - Remove the door handle from the door trim panel by pulling it back through the door trim panel. 9. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched Front Door Window Glass Weatherstrip: Customer Interest Body - Front/Rear Door Window Noise/Glass Scratched TSB 11-2-15 02/28/11 WINDOW SQUEAK NOISE AND/OR VERTICAL WINDOW GLASS SCRATCH - BUILT ON OR BEFORE 8/13/2010 FORD: 2008-2011 Escape MERCURY: 2008-2011 Mariner This article supersedes TSB 10-25-5 to update the Part List. ISSUE Some 2008-2011 Escape and Mariner vehicles built on or before 8/13/2010 may exhibit a front and/or rear window glass squeak noise with or without side window vertical window glass scratch. This may be due to a tolerance stack up condition and/or incorrect door flange adjustment. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Fully lower the affected window glass. 2. Remove the exterior door glass weatherstrip. Refer to Workshop Manual (WSM), Section 501-11 (Exploded View). 3. Fully raise the window glass. 4. Measure the distance from the inside edge of the weatherstrip flange to the outside sur[ace of the window glass. Is the distance within specification range of 1/4" (6 mm) to 3/8" (10 mm)? a. Yes - Proceed to Step 5. b. No - Using a suitable tool, evenly adjust the flange into specification. Proceed to Step 5. 5. Inspect the side window glass for evidence of vertical scratches. Are scratches present? a. Yes - Replace the affected side window glass and exterior door glass weatherstrip. Refer to WSM, Section 501-11. b. No - Replace the affected exterior door glass weatherstrip. Refer to WSM, Section 501-11. 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 110215A 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 110215B 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 6589 With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215C 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215D 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors 110215E 2008-2011 Escape, 0.5 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 11021SF 2008-2011 Escape, 1.0 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215G 2008-2011 Escape, 0.8 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215H 2008-2011 Escape, 1.5 Hrs. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 7821453 41 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 6590 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass Weatherstrip: > 10-25-4 > Dec > 10 > Body - Front Door Window Exterior Weatherstrip Deformed Front Door Window Glass Weatherstrip: Customer Interest Body - Front Door Window Exterior Weatherstrip Deformed TSB 10-25-4 12/23/10 FRONT EXTERIOR DOOR GLASS WEATHERSTRIP DEFORMED OR LIFTING - BUILT ON OR BEFORE 517/2010 12/23/10 FORD: 008-2010 Escape MERCURY: 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 5/7/2010 may exhibit the front exterior door glass weatherstrip deformed and/or lifting up from the door flange. This may be due to a lack of retention between the door glass weatherstrip and flange. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove affected front exterior door glass weatherstrip. Reference Workshop Manual (WSM), Section 501-11 Glass, Frames, and Mechanisms Exploded View. 2. Apply a strip of 3M(TM) Safety-Walk(TM) Slip-Resistant General Purpose Tapes, or similar (obtained locally) to the outer flange surface at the center of the door. Cut grip tape to approximately 2.5" X .5" (64 mm X 13 mm). (Figure 1) 3. Install new revised exterior door glass weatherstrip. Reference WSM, Section 501-11 Glass, Frames, and Mechanisms - Exploded View. 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 102504A 2008-2010 Escape, 0.2 Hr. Mariner: Replace One Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass Weatherstrip: > 10-25-4 > Dec > 10 > Body - Front Door Window Exterior Weatherstrip Deformed > Page 6595 Exterior Door Glass Weather Strip Includes Time To Install Grip Tape (Do Not Use With Any Other Labor Operations) 102504B 2008-2010 Escape, 0.3 Hr. Mariner: Replace Both Exterior Door Glass Weather Strips Includes Time To Install Grip Tape (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7821453 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched Front Door Window Glass Weatherstrip: All Technical Service Bulletins Body - Front/Rear Door Window Noise/Glass Scratched TSB 11-2-15 02/28/11 WINDOW SQUEAK NOISE AND/OR VERTICAL WINDOW GLASS SCRATCH - BUILT ON OR BEFORE 8/13/2010 FORD: 2008-2011 Escape MERCURY: 2008-2011 Mariner This article supersedes TSB 10-25-5 to update the Part List. ISSUE Some 2008-2011 Escape and Mariner vehicles built on or before 8/13/2010 may exhibit a front and/or rear window glass squeak noise with or without side window vertical window glass scratch. This may be due to a tolerance stack up condition and/or incorrect door flange adjustment. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Fully lower the affected window glass. 2. Remove the exterior door glass weatherstrip. Refer to Workshop Manual (WSM), Section 501-11 (Exploded View). 3. Fully raise the window glass. 4. Measure the distance from the inside edge of the weatherstrip flange to the outside sur[ace of the window glass. Is the distance within specification range of 1/4" (6 mm) to 3/8" (10 mm)? a. Yes - Proceed to Step 5. b. No - Using a suitable tool, evenly adjust the flange into specification. Proceed to Step 5. 5. Inspect the side window glass for evidence of vertical scratches. Are scratches present? a. Yes - Replace the affected side window glass and exterior door glass weatherstrip. Refer to WSM, Section 501-11. b. No - Replace the affected exterior door glass weatherstrip. Refer to WSM, Section 501-11. 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 110215A 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 110215B 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 6601 With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215C 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215D 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors 110215E 2008-2011 Escape, 0.5 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 11021SF 2008-2011 Escape, 1.0 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215G 2008-2011 Escape, 0.8 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215H 2008-2011 Escape, 1.5 Hrs. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 7821453 41 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 6602 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass Weatherstrip: > 10-25-4 > Dec > 10 > Body - Front Door Window Exterior Weatherstrip Deformed Front Door Window Glass Weatherstrip: All Technical Service Bulletins Body - Front Door Window Exterior Weatherstrip Deformed TSB 10-25-4 12/23/10 FRONT EXTERIOR DOOR GLASS WEATHERSTRIP DEFORMED OR LIFTING - BUILT ON OR BEFORE 517/2010 12/23/10 FORD: 008-2010 Escape MERCURY: 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 5/7/2010 may exhibit the front exterior door glass weatherstrip deformed and/or lifting up from the door flange. This may be due to a lack of retention between the door glass weatherstrip and flange. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove affected front exterior door glass weatherstrip. Reference Workshop Manual (WSM), Section 501-11 Glass, Frames, and Mechanisms Exploded View. 2. Apply a strip of 3M(TM) Safety-Walk(TM) Slip-Resistant General Purpose Tapes, or similar (obtained locally) to the outer flange surface at the center of the door. Cut grip tape to approximately 2.5" X .5" (64 mm X 13 mm). (Figure 1) 3. Install new revised exterior door glass weatherstrip. Reference WSM, Section 501-11 Glass, Frames, and Mechanisms - Exploded View. 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 102504A 2008-2010 Escape, 0.2 Hr. Mariner: Replace One Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass Weatherstrip: > 10-25-4 > Dec > 10 > Body - Front Door Window Exterior Weatherstrip Deformed > Page 6607 Exterior Door Glass Weather Strip Includes Time To Install Grip Tape (Do Not Use With Any Other Labor Operations) 102504B 2008-2010 Escape, 0.3 Hr. Mariner: Replace Both Exterior Door Glass Weather Strips Includes Time To Install Grip Tape (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7821453 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass, Frames and Mechanisms Exploded View, Front Door Front Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Front Door Glass, Frames and Mechanisms - Exploded View, Front Door 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass, Frames and Mechanisms Exploded View, Front Door > Page 6610 Front Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Front Door Glass Top Run - Front Removal and Installation 1. Remove the front door window glass. For additional information, refer to Window Glass - Front Door See: Service and Repair/Window Glass Front Door. 2. Remove the front door interior sail panel. - If equipped, disconnect the speaker electrical connector. 3. Remove the 2 front door glass top run bolts. - To install tighten to 6 Nm (53 lb-in). 4. Remove the front door glass top run. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Glass, Frames and Mechanisms - Exploded View, Front Door 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door Front Door Window Regulator: Service and Repair Glass, Frames and Mechanisms - Exploded View, Front Door Glass, Frames and Mechanisms - Exploded View, Front Door 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 6618 Front Door Window Regulator: Service and Repair Window Regulator - Front Door Window Regulator - Front Door Removal and Installation 1. Remove the front door trim panel. 2. Remove the screw and the front door trim panel bracket. 3. Remove the 3 pushpins and pad assembly. 4. NOTE: Do not touch the adhesive surface during removal or installation of the watershield, as re-bonding will be impaired. If additional adhesive is required during installation, apply seam sealer as necessary to completely seal the watershield to the inner door. Position the watershield aside. 5. Connect the window control switch electrical connector. 6. Using the window control switch, lower the front door window glass to gain access to the front door window glass screws. 7. Disconnect the window control switch electrical connector. 8. Remove the 2 front door window glass screws. - To install, tighten to 5 Nm (44 lb-in). 9. Support the front door window glass in the full UP position with tape. 10. Disconnect the front door window motor electrical connector. 11. Remove the front door window regulator and motor bolt. - To install, tighten to 11 Nm (97 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 6619 12. Loosen the 2 front door window regulator and motor bolts. - To install, tighten to 11 Nm (97 lb-in). 13. Remove the 2 nuts and the front door window regulator and motor. - To install, tighten to 11 Nm (97 lb-in). 14. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Rear Door Exterior Handle: > 09-24-7 > Dec > 09 > Body - Exterior Door Handle(s) Hard T0 Open/Not Flush Rear Door Exterior Handle: Customer Interest Body - Exterior Door Handle(s) Hard T0 Open/Not Flush TSB 09-24-7 12/14/09 EXTERIOR DOOR HANDLE DIFFICULT TO OPEN/HANDLE NOT SITTING FLUSH WHEN RELEASED/HANDLE STICKING WHEN OPENING DOOR - BUILT ON OR BEFORE 9/1/2009 FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 9/1/2009 may exhibit an exterior door handle that is difficult to open, does not sit flush when released, and/or sticks when opening door. This may be due to the exterior door handle plunger binding on the door handle bezel. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE 1. Remove the exterior door bezel on affected door(s) per Workshop Manual (WSM), Section 501-14. 2. Closely examine the exterior door bezel for signs of damage; inspect for a groove worn into the bezel due to contact with the door handle plunger. Is any damage present? (Figure 1) a. No - Do not continue with this procedure and follow WSM, Section 501-14 Symptom Chart pinpoint test T. b. Yes - Replace bezel with revised exterior door bezel as necessary following WSM, Section 501-14. Parts Block 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Rear Door Exterior Handle: > 09-24-7 > Dec > 09 > Body - Exterior Door Handle(s) Hard T0 Open/Not Flush > Page 6630 092407A 2008-2010 Escape, 0.6 Hr. Mariner: Inspect And Replace One (1) Front Bezel. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407B 2008-2010 Escape, 1.0 Hr. Mariner: Inspect And Replace Two (2) Front Bezels. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407C 2008-2010 Escape, 0.5 Hr. Mariner: Inspect And Replace One (1) Rear Bezel. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) 092407D 2008-2010 Escape, 0.8 Hr. Mariner: Inspect And Replace Two (2) Rear Bezels. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) DEALER CODING CONDITION BASIC PART NO. CODE 7822404 30 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > 09-24-7 > Dec > 09 > Body - Exterior Door Handle(s) Hard T0 Open/Not Flush Rear Door Exterior Handle: All Technical Service Bulletins Body - Exterior Door Handle(s) Hard T0 Open/Not Flush TSB 09-24-7 12/14/09 EXTERIOR DOOR HANDLE DIFFICULT TO OPEN/HANDLE NOT SITTING FLUSH WHEN RELEASED/HANDLE STICKING WHEN OPENING DOOR - BUILT ON OR BEFORE 9/1/2009 FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 9/1/2009 may exhibit an exterior door handle that is difficult to open, does not sit flush when released, and/or sticks when opening door. This may be due to the exterior door handle plunger binding on the door handle bezel. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE 1. Remove the exterior door bezel on affected door(s) per Workshop Manual (WSM), Section 501-14. 2. Closely examine the exterior door bezel for signs of damage; inspect for a groove worn into the bezel due to contact with the door handle plunger. Is any damage present? (Figure 1) a. No - Do not continue with this procedure and follow WSM, Section 501-14 Symptom Chart pinpoint test T. b. Yes - Replace bezel with revised exterior door bezel as necessary following WSM, Section 501-14. Parts Block 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > 09-24-7 > Dec > 09 > Body - Exterior Door Handle(s) Hard T0 Open/Not Flush > Page 6636 092407A 2008-2010 Escape, 0.6 Hr. Mariner: Inspect And Replace One (1) Front Bezel. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407B 2008-2010 Escape, 1.0 Hr. Mariner: Inspect And Replace Two (2) Front Bezels. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407C 2008-2010 Escape, 0.5 Hr. Mariner: Inspect And Replace One (1) Rear Bezel. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) 092407D 2008-2010 Escape, 0.8 Hr. Mariner: Inspect And Replace Two (2) Rear Bezels. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) DEALER CODING CONDITION BASIC PART NO. CODE 7822404 30 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > Page 6637 Rear Door Exterior Handle: By Symptom Technical Service Bulletin # 09-24-7 Date: 091214 Body - Exterior Door Handle(s) Hard T0 Open/Not Flush TSB 09-24-7 12/14/09 EXTERIOR DOOR HANDLE DIFFICULT TO OPEN/HANDLE NOT SITTING FLUSH WHEN RELEASED/HANDLE STICKING WHEN OPENING DOOR - BUILT ON OR BEFORE 9/1/2009 FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 9/1/2009 may exhibit an exterior door handle that is difficult to open, does not sit flush when released, and/or sticks when opening door. This may be due to the exterior door handle plunger binding on the door handle bezel. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE 1. Remove the exterior door bezel on affected door(s) per Workshop Manual (WSM), Section 501-14. 2. Closely examine the exterior door bezel for signs of damage; inspect for a groove worn into the bezel due to contact with the door handle plunger. Is any damage present? (Figure 1) a. No - Do not continue with this procedure and follow WSM, Section 501-14 Symptom Chart pinpoint test T. b. Yes - Replace bezel with revised exterior door bezel as necessary following WSM, Section 501-14. Parts Block 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > Page 6638 OPERATION DESCRIPTION TIME 092407A 2008-2010 Escape, 0.6 Hr. Mariner: Inspect And Replace One (1) Front Bezel. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407B 2008-2010 Escape, 1.0 Hr. Mariner: Inspect And Replace Two (2) Front Bezels. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407C 2008-2010 Escape, 0.5 Hr. Mariner: Inspect And Replace One (1) Rear Bezel. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) 092407D 2008-2010 Escape, 0.8 Hr. Mariner: Inspect And Replace Two (2) Rear Bezels. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) DEALER CODING CONDITION BASIC PART NO. CODE 7822404 30 Disclaimer Technical Service Bulletin # 09-24-7 Date: 091214 Body - Exterior Door Handle(s) Hard T0 Open/Not Flush TSB 09-24-7 12/14/09 EXTERIOR DOOR HANDLE DIFFICULT TO OPEN/HANDLE NOT SITTING FLUSH WHEN RELEASED/HANDLE STICKING WHEN OPENING DOOR - BUILT ON OR BEFORE 9/1/2009 FORD: 2008-2010 Escape MERCURY: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > Page 6639 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 9/1/2009 may exhibit an exterior door handle that is difficult to open, does not sit flush when released, and/or sticks when opening door. This may be due to the exterior door handle plunger binding on the door handle bezel. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE 1. Remove the exterior door bezel on affected door(s) per Workshop Manual (WSM), Section 501-14. 2. Closely examine the exterior door bezel for signs of damage; inspect for a groove worn into the bezel due to contact with the door handle plunger. Is any damage present? (Figure 1) a. No - Do not continue with this procedure and follow WSM, Section 501-14 Symptom Chart pinpoint test T. b. Yes - Replace bezel with revised exterior door bezel as necessary following WSM, Section 501-14. Parts Block 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 092407A 2008-2010 Escape, 0.6 Hr. Mariner: Inspect And Replace One (1) Front Bezel. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407B 2008-2010 Escape, 1.0 Hr. Mariner: Inspect And Replace Two (2) Front Bezels. This Labor Operation Can Be Claimed With C Or D (If The New Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > Page 6640 Bezel Requires Paint Use B-Time) 092407C 2008-2010 Escape, 0.5 Hr. Mariner: Inspect And Replace One (1) Rear Bezel. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) 092407D 2008-2010 Escape, 0.8 Hr. Mariner: Inspect And Replace Two (2) Rear Bezels. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) DEALER CODING CONDITION BASIC PART NO. CODE 7822404 30 Disclaimer Technical Service Bulletin # 09-24-7 Date: 091214 Body - Exterior Door Handle(s) Hard T0 Open/Not Flush TSB 09-24-7 12/14/09 EXTERIOR DOOR HANDLE DIFFICULT TO OPEN/HANDLE NOT SITTING FLUSH WHEN RELEASED/HANDLE STICKING WHEN OPENING DOOR - BUILT ON OR BEFORE 9/1/2009 FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 9/1/2009 may exhibit an exterior door handle that is difficult to open, does not sit flush when released, and/or sticks when opening door. This may be due to the exterior door handle plunger binding on the door handle bezel. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE 1. Remove the exterior door bezel on affected door(s) per Workshop Manual (WSM), Section 501-14. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > Page 6641 2. Closely examine the exterior door bezel for signs of damage; inspect for a groove worn into the bezel due to contact with the door handle plunger. Is any damage present? (Figure 1) a. No - Do not continue with this procedure and follow WSM, Section 501-14 Symptom Chart pinpoint test T. b. Yes - Replace bezel with revised exterior door bezel as necessary following WSM, Section 501-14. Parts Block 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 092407A 2008-2010 Escape, 0.6 Hr. Mariner: Inspect And Replace One (1) Front Bezel. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407B 2008-2010 Escape, 1.0 Hr. Mariner: Inspect And Replace Two (2) Front Bezels. This Labor Operation Can Be Claimed With C Or D (If The New Bezel Requires Paint Use B-Time) 092407C 2008-2010 Escape, 0.5 Hr. Mariner: Inspect And Replace One (1) Rear Bezel. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) 092407D 2008-2010 Escape, 0.8 Hr. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > Page 6642 Mariner: Inspect And Replace Two (2) Rear Bezels. This Labor Operation Can Be Claimed With A Or B (If The New Bezel Requires Paint Use B-Time) DEALER CODING CONDITION BASIC PART NO. CODE 7822404 30 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 > Door Handle Reinforcement - Exterior, Rear Rear Door Exterior Handle: Service and Repair Door Handle Reinforcement - Exterior, Rear Door Handle Reinforcement - Exterior, Rear Removal and Installation NOTE: The door glass must be completely raised. 1. Remove the exterior rear door handle. For additional information, refer to Exterior Rear Door Handle See: Exterior Rear Door Handle. 2. Disconnect the door latch carrier. 1. Release the retainer and position the door latch carrier aside. 2. Remove the exterior rear door handle reinforcement screw. 3. Disconnect the exterior rear door handle reinforcement actuating rod from the rear door latch. 4. Remove the exterior rear door handle reinforcement with the exterior rear door handle reinforcement actuating rod. 5. If necessary, remove the exterior rear door handle reinforcement actuating rod. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 > Door Handle Reinforcement - Exterior, Rear > Page 6645 Rear Door Exterior Handle: Service and Repair Exterior Rear Door Handle Exterior Rear Door Handle Removal and Installation 1. Remove the rear door trim panel. 2. Position the watershield aside. 3. Remove the rear window channel bolt and position the window channel aside. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the exterior rear door handle cover retaining screw from the door handle reinforcement. 5. Remove the exterior rear door handle bezel. 1. Pull the exterior rear door handle open. 2. Pivot the rear of the exterior rear door handle bezel and remove. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 > Door Handle Reinforcement - Exterior, Rear > Page 6646 6. Remove the exterior rear door handle. - Open and pull the exterior rear door handle rearward to release and remove. 7. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 > Door Handle Reinforcement - Exterior, Rear > Page 6647 Rear Door Exterior Handle: Service and Repair Rear Door Handles, Locks and Latches - Exploded View Rear Door Handles, Locks and Latches - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair Rear Door Interior Handle: Service and Repair Interior Door Handle - Rear Removal and Installation 1. Remove the rear door trim panel. 2. Release the rear interior door handle retaining tabs and remove the rear interior door handle from the door trim panel. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Adjustments Rear Door Hinge: Adjustments Door Alignment - Rear NOTE: Driver side shown, passenger side similar. All alignments 1. Remove the door latch striker plate. Rear door in and out, up and down alignment 2. Loosen, but do not remove, the rear door hinge-to-rear door fasteners enough to allow door alignment. Front door fore, aft and tilt alignment 3. Loosen, but do not remove, the upper rear door hinge-to-body fasteners enough to allow door alignment. 4. Remove the front door scuff plate. 5. Remove the rear door scuff plate. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Adjustments > Page 6654 6. Position aside the lower B-pillar trim panel. 7. Loosen the rear door hinge-to-body bolts inside at the inside B-pillar. 8. Loosen, but do not remove, the lower rear door hinge-to-body fasteners enough to allow door alignment. All alignments 9. Adjust the door. 10. Tighten the door fasteners. - Tighten the rear door hinge-to-rear door fasteners to 24 Nm (18 lb-ft). - Tighten the rear door hinge-to-body fasteners to 24 Nm (18 lb-ft). 11. Install and adjust the door striker as necessary. - Tighten the door latch striker plate bolts to 30 Nm (22 lb-ft). - To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Procedures Rear Door Latch: Procedures Latch Lubrication 1. Open the door. 2. Using a screwdriver, fully close the latch (two clicks). 3. Spray the multi-purpose grease into the opening on the door latch for approximately 5 seconds. 4. Open the latch using either the interior or exterior door handle. 5. Open and close the door several times to circulate the lubricant inside the latch. 6. Wipe off any excess grease. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Procedures > Page 6659 Rear Door Latch: Removal and Replacement Rear Door Handles, Locks and Latches - Exploded View Rear Door Handles, Locks and Latches - Exploded View 1. For additional information, refer to the procedures. Rear Door Latch Rear Door Latch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Procedures > Page 6660 Removal and Installation NOTE: The rear door window glass must be completely raised. 1. Remove rear door trim panel. 2. Position the water shield aside. 3. Remove the exterior rear door handle reinforcement. For additional information, refer to Door Handle Reinforcement - Exterior, Rear See: Rear Door Handle/Rear Door Exterior Handle/Service and Repair/Door Handle Reinforcement - Exterior, Rear. 4. Remove and discard the 3 rear door latch bolts. - To install, tighten to 12 Nm (106 lb-in). 5. Disconnect the rear door latch electrical connector. 6. Remove the rear door latch. - Slide the rear door latch toward the front of the vehicle. - Remove the rear door latch with the door lock actuating rod and the interior door handle actuating cable. 7. If necessary, remove the door lock actuating rod and the interior door handle actuating cable. 8. To install, reverse the removal procedure. - Lubricate the rear door latch to striker surfaces after installation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Door Trim Panel - Rear NOTE: Escape shown, Mariner similar. Removal and Installation NOTE: LH side shown, RH side similar. 1. Open and remove the door handle finish panel. 2. Remove the door handle screw. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 6664 3. Remove the door pull cup screw cover. 4. Remove the door pull cup screw. 5. Remove the 3 door trim panel screws. 6. Remove the door trim panel. - Pull outward and then upward on the door trim panel. - Disconnect the electrical connector. 7. Remove the door handle from the door trim panel. - Press the 2 retaining tabs while pushing the door handle from the door trim panel. - Remove the door handle from the door trim panel by pulling it back through the door trim panel. 8. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched Rear Door Window Glass Weatherstrip: Customer Interest Body - Front/Rear Door Window Noise/Glass Scratched TSB 11-2-15 02/28/11 WINDOW SQUEAK NOISE AND/OR VERTICAL WINDOW GLASS SCRATCH - BUILT ON OR BEFORE 8/13/2010 FORD: 2008-2011 Escape MERCURY: 2008-2011 Mariner This article supersedes TSB 10-25-5 to update the Part List. ISSUE Some 2008-2011 Escape and Mariner vehicles built on or before 8/13/2010 may exhibit a front and/or rear window glass squeak noise with or without side window vertical window glass scratch. This may be due to a tolerance stack up condition and/or incorrect door flange adjustment. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Fully lower the affected window glass. 2. Remove the exterior door glass weatherstrip. Refer to Workshop Manual (WSM), Section 501-11 (Exploded View). 3. Fully raise the window glass. 4. Measure the distance from the inside edge of the weatherstrip flange to the outside sur[ace of the window glass. Is the distance within specification range of 1/4" (6 mm) to 3/8" (10 mm)? a. Yes - Proceed to Step 5. b. No - Using a suitable tool, evenly adjust the flange into specification. Proceed to Step 5. 5. Inspect the side window glass for evidence of vertical scratches. Are scratches present? a. Yes - Replace the affected side window glass and exterior door glass weatherstrip. Refer to WSM, Section 501-11. b. No - Replace the affected exterior door glass weatherstrip. Refer to WSM, Section 501-11. 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 110215A 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 110215B 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 6674 With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215C 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215D 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors 110215E 2008-2011 Escape, 0.5 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 11021SF 2008-2011 Escape, 1.0 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215G 2008-2011 Escape, 0.8 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215H 2008-2011 Escape, 1.5 Hrs. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 7821453 41 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 6675 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched Rear Door Window Glass Weatherstrip: All Technical Service Bulletins Body - Front/Rear Door Window Noise/Glass Scratched TSB 11-2-15 02/28/11 WINDOW SQUEAK NOISE AND/OR VERTICAL WINDOW GLASS SCRATCH - BUILT ON OR BEFORE 8/13/2010 FORD: 2008-2011 Escape MERCURY: 2008-2011 Mariner This article supersedes TSB 10-25-5 to update the Part List. ISSUE Some 2008-2011 Escape and Mariner vehicles built on or before 8/13/2010 may exhibit a front and/or rear window glass squeak noise with or without side window vertical window glass scratch. This may be due to a tolerance stack up condition and/or incorrect door flange adjustment. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Fully lower the affected window glass. 2. Remove the exterior door glass weatherstrip. Refer to Workshop Manual (WSM), Section 501-11 (Exploded View). 3. Fully raise the window glass. 4. Measure the distance from the inside edge of the weatherstrip flange to the outside sur[ace of the window glass. Is the distance within specification range of 1/4" (6 mm) to 3/8" (10 mm)? a. Yes - Proceed to Step 5. b. No - Using a suitable tool, evenly adjust the flange into specification. Proceed to Step 5. 5. Inspect the side window glass for evidence of vertical scratches. Are scratches present? a. Yes - Replace the affected side window glass and exterior door glass weatherstrip. Refer to WSM, Section 501-11. b. No - Replace the affected exterior door glass weatherstrip. Refer to WSM, Section 501-11. 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 110215A 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 110215B 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 6681 With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215C 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215D 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors 110215E 2008-2011 Escape, 0.5 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 11021SF 2008-2011 Escape, 1.0 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215G 2008-2011 Escape, 0.8 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215H 2008-2011 Escape, 1.5 Hrs. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 7821453 41 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 6682 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear Rear Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Rear Door Glass Top Run - Rear Removal and Installation 1. Remove the rear door window regulator. For additional information, refer to Window Regulator Rear Door See: Rear Door Window Regulator/Service and Repair/Window Regulator - Rear Door. 2. Position the rear door window glass to the full DOWN position. 3. Remove the 2 screws and the rear door exterior sail panel. 4. Remove the interior door glass weatherstrip. 5. Remove the exterior door glass weatherstrip. 6. Remove the rear door glass top run bolt. - To install, tighten to 6 Nm (53 lb-in). 7. Position the rear door window glass down and forward. 8. Remove the rear door glass top run. 9. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear > Page 6685 Rear Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Rear Door Glass, Frames and Mechanisms - Exploded View, Rear Door 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair Glass, Frames and Mechanisms - Exploded View, Rear Door 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door Rear Door Window Regulator: Service and Repair Glass, Frames and Mechanisms - Exploded View, Rear Door Glass, Frames and Mechanisms - Exploded View, Rear Door 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door > Page 6693 Rear Door Window Regulator: Service and Repair Window Regulator - Rear Door Window Regulator - Rear Door Removal and Installation 1. Remove the rear door trim panel. 2. Remove the screw and the rear door trim panel bracket. 3. NOTE: Do not touch the adhesive surface during removal or installation of the watershield, as re-bonding will be impaired. If additional adhesive is required during installation, apply seam sealer as necessary to completely seal the watershield to the inner door. Position the watershield aside. 4. Connect the window control switch electrical connector. 5. Using the window control switch, lower the rear door window glass to gain access to the rear door window glass screws. 6. Disconnect the window control switch electrical connector. 7. Remove the 2 rear door window glass screws. - To install, tighten to 5 Nm (44 lb-in). 8. Support the rear door window glass in the full UP position with tape. 9. Disconnect the rear door window motor electrical connector. 10. Remove the rear door window regulator and motor bolt. - To install, tighten to 11 Nm (97 lb-in). 11. Loosen the 2 rear door window regulator and motor bolts. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door > Page 6694 - To install, tighten to 11 Nm (97 lb-in). 12. Remove the 2 nuts and the rear door window regulator and motor. - To install, tighten to 6 Nm (53 lb-in). 13. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Hood Latch: Service and Repair Hood Latch Hood Latch Removal 1. NOTE: Do not remove the nut. Loosen the hood latch nut. 2. NOTE: Mark the hood latch position prior to removal of the hood latch bolts. Remove the 2 hood latch bolts. 3. Disconnect the hood latch release cable. 1. Release the cable conduit. 2. Disconnect the cable. 4. Remove the hood latch. 5. If necessary, remove the hood latch release lever. Installation 1. Connect the hood latch release cable to the hood latch. 1. Connect the cable. 2. Engage the cable conduit. 2. Slide the hood latch down onto the mounting bracket. 3. NOTE: When the hood latch is installed, the latch adjustment must be checked to make sure the latch is installed and aligned correctly. Position the hood latch with the alignment marks and install the 2 hood latch bolts. - Tighten to 11 Nm (97 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch > Page 6700 4. Tighten the hood latch nut to 6 Nm (53 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch > Page 6701 Hood Latch: Service and Repair Hood Latch and Components - Exploded View Hood Latch and Components - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair > Hood Latch and Components - Exploded View Hood Latch Release: Service and Repair Hood Latch and Components - Exploded View Hood Latch and Components - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair > Hood Latch and Components - Exploded View > Page 6706 Hood Latch Release: Service and Repair Hood Latch Release Handle Hood Latch Release Handle Removal and Installation 1. Remove the hood latch. For additional information, refer to Hood Latch See: Hood Latch/Service and Repair/Hood Latch. 2. Disconnect the 3 hood latch release handle cable guides. - Note the routing of the hood latch release cable. 3. Remove the hood latch release handle bolt. - To install, tighten to 11 Nm (97 lb-in). 4. NOTE: Breaking the tab does not require handle assembly replacement. Using a suitable tool, push up on the tab to snap it off and then slide the handle off the instrument panel. 5. NOTE: The hood latch release handle and cable assembly must be pulled through the cowl panel into the passenger compartment. Remove the hood latch release handle and cable assembly. - Pull the hood latch release cable through the cowl panel. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Window Glass - Liftgate Removal and Installation 1. Open the liftgate window glass. 2. Remove the 2 liftgate window glass nut access covers. 3. Through the RH access, disconnect the liftgate window glass electrical harness connector. 4. Disconnect the LH heated window grid wire electrical connector. 5. NOTE: An assistant may be needed to carry out this step. Disconnect the 2 liftgate window glass cylinders. 1. Slide the spring retainer to the end of the socket. 2. Disconnect the socket from the ball stud. 6. NOTE: An assistant may be needed to carry out this step. Remove the 2 liftgate window glass hinge nuts and the liftgate window glass. - To install, tighten to 11 Nm (97 lb-in). 7. To install, reverse the removal procedure. - Transfer components as necessary. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 6714 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Service and Repair > Liftgate Release Switch Power Trunk / Liftgate Lock Switch: Service and Repair Liftgate Release Switch Liftgate Release Switch Removal and Installation 1. Remove the liftgate trim panel. 2. Remove the 4 liftgate trim bezel nuts and remove the bezel from the liftgate. - To install, tighten to 8 Nm (71 lb-in). - Disconnect the electrical connector. - Using the appropriate tool, press the tabs and remove the liftgate release switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Service and Repair > Liftgate Release Switch > Page 6720 Power Trunk / Liftgate Lock Switch: Service and Repair Liftgate Release Switch - Liftgate Window Liftgate Release Switch - Liftgate Window Removal and Installation 1. Remove the liftgate trim panel. 2. Remove the 4 liftgate trim bezel nuts and remove the bezel from the liftgate. - To install, tighten to 8 Nm (71 lb-in). - Disconnect the liftgate window release switch electrical connector. - Using the appropriate tool, press the tabs and remove the liftgate window release switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch > Component Information > Locations > Page 6724 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair Trunk / Liftgate Handle: Service and Repair Liftgate Handle, Lock and Latch - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair Trunk / Liftgate Interior Trim Panel: Service and Repair Liftgate Trim Panel Removal and Installation 1. Open the liftgate. 2. Remove the 4 liftgate trim panel screws. 3. Release the 8 liftgate trim panel retaining clips. 4. NOTE: If equipped with a rear wiper, the rear glass must be open. Remove the liftgate trim panel. 5. NOTICE: To avoid damage to the liftgate trim panel, remove any retaining clips from the body and attach the to the liftgate trim panel before installing. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View Trunk / Liftgate Latch: Service and Repair Liftgate Handle, Lock and Latch - Exploded View Liftgate Handle, Lock and Latch - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 6735 Trunk / Liftgate Latch: Service and Repair Liftgate Latch Liftgate Latch Removal and Installation 1. Remove the liftgate trim panel. 2. Disconnect the liftgate latch electrical connectors. 3. Remove and discard the 3 liftgate latch bolts. - To install, tighten to 12 Nm (106 lb-in). 4. Remove the liftgate latch. 5. To install, reverse the removal procedure. - Lubricate the liftgate latch to striker surfaces after installation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 6736 Trunk / Liftgate Latch: Service and Repair Liftgate Window Latch Liftgate Window Latch Removal and Installation NOTE: Make sure the liftgate window glass is in the raised position. 1. Remove the liftgate trim panel. 2. Disconnect the liftgate window latch ajar switch electrical connector. 3. NOTE: Mark the position of the liftgate window latch prior to removing the liftgate window latch bolts. Remove the 2 bolts and the liftgate window latch. - To install, tighten to 12 Nm (106 lb-in). 4. NOTE: The liftgate window latch must be checked to make sure the latch is installed and aligned correctly. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock > System Information > Service and Repair Trunk / Liftgate Lock: Service and Repair Liftgate Handle, Lock and Latch - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Switch: > 10-5-1 > Mar > 10 > Body - Uncommanded Liftgate Opening Trunk / Liftgate Switch: Customer Interest Body - Uncommanded Liftgate Opening TSB 10-5-1 03/29/10 LIFTGATE OPENING UN-COMMANDED OR NOT OPENING WHEN COMMANDED WHEN PARKED - INTERMITTENT FORD: 2008-2009 Escape MERCURY: 2008-2009 Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles built on or before 8/31/2008 may exhibit the liftgate opening un-commanded, or not opening when commanded while vehicle is parked. This may be due to water intrusion into the switch connector causing corrosion at the liftgate rear switch. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Refer to Workshop Manual (WSM), Section 501-14 for additional diagnostics. 1. Remove the liftgate trim panel. Refer to WSM, Section 501-05. 2. Remove the four (4) liftgate trim bezel nuts and remove the bezel from the liftgate. 3. Closely inspect the liftgate release switch and harness connector pins for signs of water intrusion and/or corrosion. Is any evidence of water intrusion or corrosion present? (Figure 1) a. No - Do not continue with this procedure. Refer to WSM, Section 501-14 for additional diagnostics. b. Yes - Replace the liftgate release switch per WSM, Section 501-14, and install new Pigtail Wiring Kit per Wiring Diagram, Section 5-1. Parts Block 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Switch: > 10-5-1 > Mar > 10 > Body - Uncommanded Liftgate Opening > Page 6751 100S01A 2008-2009 Escape, 0.6 Hr. Mariner: Replace The Liftgate Release Switch And The Wiring Pigtail (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 13412 12 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Switch: > 10-5-1 > Mar > 10 > Body - Uncommanded Liftgate Opening Trunk / Liftgate Switch: All Technical Service Bulletins Body - Uncommanded Liftgate Opening TSB 10-5-1 03/29/10 LIFTGATE OPENING UN-COMMANDED OR NOT OPENING WHEN COMMANDED WHEN PARKED - INTERMITTENT FORD: 2008-2009 Escape MERCURY: 2008-2009 Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles built on or before 8/31/2008 may exhibit the liftgate opening un-commanded, or not opening when commanded while vehicle is parked. This may be due to water intrusion into the switch connector causing corrosion at the liftgate rear switch. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Refer to Workshop Manual (WSM), Section 501-14 for additional diagnostics. 1. Remove the liftgate trim panel. Refer to WSM, Section 501-05. 2. Remove the four (4) liftgate trim bezel nuts and remove the bezel from the liftgate. 3. Closely inspect the liftgate release switch and harness connector pins for signs of water intrusion and/or corrosion. Is any evidence of water intrusion or corrosion present? (Figure 1) a. No - Do not continue with this procedure. Refer to WSM, Section 501-14 for additional diagnostics. b. Yes - Replace the liftgate release switch per WSM, Section 501-14, and install new Pigtail Wiring Kit per Wiring Diagram, Section 5-1. Parts Block 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Switch: > 10-5-1 > Mar > 10 > Body - Uncommanded Liftgate Opening > Page 6757 100S01A 2008-2009 Escape, 0.6 Hr. Mariner: Replace The Liftgate Release Switch And The Wiring Pigtail (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 13412 12 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > Page 6758 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > Page 6759 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 2 wiper pivot arms nuts. - To install, tighten to 35 Nm (26 lb-ft). 2. Remove the LH and RH wiper pivot arms. 3. Remove the LH and RH cowl end cap pushpin retainers. 4. Remove the cowl end caps. 5. Release the cowl panel grille from the retaining clips and remove the cowl panel grille. 6. To install, reverse the removal procedure. - Adjust the wiper pivot arms. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Bracket > Component Information > Service and Repair License Plate Bracket: Service and Repair License Plate Housing 1. Remove the liftgate trim panel. 2. Disconnect the license plate housing electrical connector. 3. Remove the license plate housing retaining nuts (4 required). 4. Release the license plate housing from the push clips and remove the license plate housing from the liftgate. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Fender Splash Shield Front Fender Liner: Service and Repair Fender Splash Shield Fender Splash Shield Removal and Installation 1. Remove the 3 fender splash shield bolts. - To install, tighten to 5 Nm (44 lb-in). 2. Remove the 7 fender splash shield pin-type retainers. 3. Remove the 6 fender splash shield screws. - To install, tighten to 5 Nm (44 lb-in). 4. Remove the fender splash shield. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Fender Splash Shield > Page 6773 Front Fender Liner: Service and Repair Front End Body Panels - Exploded View Front End Body Panels - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation Body / Frame Mount Bushing: Description and Operation Subframe and Mounting Systems Front Subframe The front subframe is bolted to the body and is used to: - aid in structural support. - provide mounting surfaces for the front suspension control arms. - provide a mounting point for the engine isolators. - provide the mounting surface for the steering gear. - provide the mounting surface for the sway bar. Rear Subframe The rear subframe is bolted to the body and is used to: - aid in structural support. - provide mounting surfaces for the rear suspension control arms. - provide mounting surfaces for the rear differential All-Wheel Drive (AWD). Welding Precautions The correct equipment and settings must be used when welding mild or high strength steel. Metal Inert Gas (MIG) and resistance spot welding are the preferred methods. Surfaces must be clean and free of foreign materials. - Do not weld on the subframe. - The correct protective clothing should always be worn. - Adequate ventilation must be provided to avoid accumulation of poisonous gases. - A test weld should always be carried out on a test sample. - Follow equipment manufacturer's prescribed procedures and equipment settings for the type of weld being used. - Disconnect the battery ground cable from the battery. - On Hybrid vehicles, depower the high voltage traction battery system. Refer to Hybrid Drive Systems. - Disconnect on-vehicle modules and protect them from possible heat damage and electrical currents when welding. - Corrosion protection needs to be restored whenever it is necessary to sand or grind through painted surfaces or E-coat, or when bare metal repairs are carried out. Refer to Restoring Corrosion Protection Following Repair. Underbody misalignment can affect front and rear wheel alignment, the operation of the suspension parts and drivetrain operation. Window glass cracks, door and window opening concerns, and air or water leaks at the doors are often caused by incorrectly tightened bolts and body misalignment. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > Customer Interest for Front Cross-Member: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration Front Cross-Member: Customer Interest Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > Customer Interest for Front Cross-Member: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration > Page 6787 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration Front Cross-Member: All Technical Service Bulletins Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration > Page 6793 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > Page 6794 Front Cross-Member: By Symptom Technical Service Bulletin # 09-22-19 Date: 091116 Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > Page 6795 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Technical Service Bulletin # 09-22-19 Date: 091116 Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > Page 6796 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > Page 6797 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Technical Service Bulletin # 09-22-19 Date: 091116 Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > Page 6798 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member: > Page 6799 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > Customer Interest: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration Front Cross-Member Bushing: Customer Interest Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > Customer Interest: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration > Page 6808 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member Bushing: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration Front Cross-Member Bushing: All Technical Service Bulletins Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Cross-Member Bushing: > 09-22-19 > Nov > 09 > Body/Frame - Engine Moan/Drone Noise On Acceleration > Page 6814 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Cross-Member Bushing: > 09-12-16 > Jun > 09 > 4X4 System - PTU Whining Noise At 60-70 MPH Vibration Damper: All Technical Service Bulletins 4X4 System - PTU Whining Noise At 60-70 MPH TSB 09-12-16 06/29/09 4WD, AUTOMATIC TRANSMISSION - WHINE NOISE 60-70 MPH (96-112 KM/H) FORD: 2009 Escape MERCURY: 2009 Mariner ISSUE Some 2009 Escape and Mariner vehicles equipped with automatic transmission and four wheel drive (4WD) system may exhibit a whine noise from the power transfer unit (PTU) at highway speeds 60-70 MPH (96-112 Km/h). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Add a mass damper to the lower, rear, transaxle support insulator. Refer to Workshop Manual (WSM), Section 307-01A: Automatic Transaxle/Transmission. 1. Remove the lower, rear, transaxle support insulator through-bolt. (Figure 1) 2. Add the mass damper to the lower, rear, transaxle support insulator. (Figure 2) 3. Install the through bolt and tighten to 85 +/- 13 lb-ft (115 +/- 17 N.m). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Cross-Member Bushing: > 09-12-16 > Jun > 09 > 4X4 System - PTU Whining Noise At 60-70 MPH > Page 6820 Parts Block 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 091216A 2009 Escape, Mariner 0.2 Hr. 4WD 2.5L Engine: Install Mass Damper Following Service Procedure (Do Not Use With 6038A) 091216A 2009 Escape, Mariner 0.3 Hr. 4WD 3.0L Engine: Install Mass Damper Following Service Procedure (Do Not Use With 6038A) DEALER CODING CONDITION BASIC PART NO. CODE 6068 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Cross-Member Bushing: > Page 6821 Front Cross-Member Bushing: By Symptom Technical Service Bulletin # 09-22-19 Date: 091116 Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Cross-Member Bushing: > Page 6822 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Technical Service Bulletin # 09-22-19 Date: 091116 Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Cross-Member Bushing: > Page 6823 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Cross-Member Bushing: > Page 6824 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Technical Service Bulletin # 09-22-19 Date: 091116 Body/Frame - Engine Moan/Drone Noise On Acceleration TSB 09-22-19 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Cross-Member Bushing: > Page 6825 11/16/09 ENGINE NOISE, DRONE/MOAN SOUND 1800-2300 RPM - BUILT ON OR BEFORE 8/10/2009 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner ISSUE Some 2009-2010 Escape Hybrid and Mariner Hybrid vehicles built on or before 8/10/2009 may exhibit a slightly louder than normal drone/moan noise on acceleration at approximately 1800-2300 RPM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disable the vehicle high voltage electrical system following Workshop Manual (WSM), Section 414-03 High voltage traction battery systems depowering. 2. Remove the lower transaxle insulator through bolt. (Figure 1) 3. Remove the rear roll restrictor-to-crossmember through bolt. (Figure 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member Bushing > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Cross-Member Bushing: > Page 6826 4. Remove the nut, bolts and engine support crossmember. Discard the nut. (Figure 3) 5. Replace the engine support crossmember with improved service level crossmember. Tighten the bolts to 66 lb-ft. (90 N.m), tighten the new nut to 129 lb-ft. (175 N.m). (Figure 3) NOTE THIS PART IS ONLY APPLICABLE TO 2009-2010 VEHICLES BUILT BEFORE 8/10/2009, AND WILL NOT CORRECT ANY OTHER SYMPTOM. 6. Install the rear roll restrictor-to-crossmember through bolt. Tighten to 66 lb-ft. (90 N.m). (Figure 2) 7. Install the lower transaxle insulator through bolt. Tighten to 85 lb-ft. (115 N.m). (Figure 1) 8. Enable the vehicle high voltage electrical system following WSM, Section 414-03. Parts Block 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 092219A 2009-2010 Escape Hybrid, 0.6 Hr. Mariner Hybrid: Replace The Engine Support Cross Member (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6P094 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Customer Interest: > 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Customer Interest: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 6836 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Customer Interest: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 6837 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 (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) 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 6843 (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 (L4-2.5L Hybrid (2009)) 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 6844 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Subframe: > 11-1-5 > Jan > 11 > Emissions - Rough Running/Hard Start/DTC's Set Canister Purge Control Valve: All Technical Service Bulletins Emissions - Rough Running/Hard Start/DTC's Set TSB 11-1-5 01/25/11 RUNS ROUGH, HARD START AFTER REFUELING, AUDIBLE CLICKING NOISE UNDER HOOD, AND/OR DTCS P0316, P144A, P1450, PO17X, P044X, P045X, BUILT ON OR BEFORE 11/1/2010 FORD: 2010-2011 Fusion 2009-2010 F-150 2009-2011 E-Series, Escape, Expedition 2011 F-250, F-350 LINCOLN: 2011 MKZ 2009-2011 Navigator MERCURY: 2010-2011 Milan 2009-2011 Mariner ISSUE Some 2009-2010 F-150, 2009-2011 Expedition, Navigator, E-Series, Escape Hybrid, Mariner Hybrid, 2010-2011 Fusion Hybrid, Milan Hybrid, 2011 MKZ Hybrid and F-Super Duty 250/350 equipped with a 6.2L engine and built on or before 11/1/2010, may exhibit a running rough concern, hard start after refueling, audible clicking noise under the hood and/or diagnostic trouble codes (DTCs) P0316, P144A, P1450, PO17X, P044X, P045X. ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE Replace the Evaporative Emission Canister Purge Valve. Refer to Workshop Manual, Section 303-13. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Subframe: > 11-1-5 > Jan > 11 > Emissions - Rough Running/Hard Start/DTC's Set > Page 6850 OPERATION DESCRIPTION TIME 110105A 2009-2011 Expedition, 0.6 Hr. Navigator, And Econoline 2009-2010 F-150: Check DTCs, And Replace The Evaporative Emission Canister Purge Valve (Do Not Use With Any Other Labor Operations) 110105A 2009-2011 Escape Hybrid, 0.7 Hr. Mariner Hybrid, 2010-2011 Fusion Hybrid, Milan Hybrid, 2011 MKZ Hybrid, And 2011 F-Super Duty 6.2L: Check DTCs, And Replace The Evaporative Emission Canister Purge Valve (Do Not Use With Any Other Labor Operations) 110105A 2009-2011 Econoline: 0.9 Hr. Check DTCs, And Replace The Evaporative Emission Canister Purge Valve (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 9C915 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Subframe: > Page 6851 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Subframe: > Page 6852 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Subframe: > Page 6853 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Subframe: > Page 6854 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Subframe: > Page 6855 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Subframe: > Page 6856 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 6857 Front Subframe: Service and Repair SUBFRAME - FRONT Special Tool(s) Removal and Installation NOTE: Escape All-Wheel Drive (AWD) shown, all other vehicles similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 6858 Escape All-Wheel Drive (AWD) Shown, All Other Vehicles Similar NOTE: Escape and Mariner only. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 6859 Escape And Mariner Only NOTE: Escape Hybrid only. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 6860 Escape Hybrid Only All vehicles NOTICE: Suspension and subframe fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 6861 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Turn the wheels to the straight ahead position and remove the key. Hybrid vehicles 3. Disconnect the high-voltage traction battery. For additional information, refer to Hybrid Drive Systems. 4. Remove the rear transmission insulator and retainer. All vehicles 5. Remove the front tires. 6. NOTICE: - Do not reuse the Constant Velocity (CV) joint bolts and washers. Install new bolts and washers or damage to the vehicle may occur. - Do not reuse the bolts and cap straps for the center U-joint. Install new bolts and cap straps or damage to the vehicle may occur. NOTE: Index-mark the front driveshaft to the center bearing. Remove the front driveshaft, if equipped. Remove the 6 front driveshaft-to-transfer case bolts and washers. Discard the bolts and washers. To install, tighten to 37 Nm (27 lb-ft). - Remove the 4 U-joint cap strap bolts and 2 cap straps and remove the front driveshaft. Discard the U-joint cap strap bolts and cap straps. To install, tighten to 23 Nm (17 lb-ft). 7. Remove the 4 bolts (2 each side) and the lateral support crossmember. - To install, tighten to 115 Nm (85 lb-ft). 8. Remove the exhaust flexible pipe (2.3L) or the dual converter Y-pipe (3.0L). 9. Remove the 6 bolts and the scrivet from the LH splash shield and remove the splash shield. 10. Remove the engine support crossmember front insulator bolt. - To install, tighten to 115 Nm (85 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 6862 11. Remove the 2 engine support crossmember bolts. - To install, tighten to 90 Nm (66 lb-ft). Hybrid vehicles only 12. Remove the 2 bolts from the lower transmission insulator and retainer bracket. All vehicles 13. Remove the nut and the engine support crossmember. Discard the nut. - To install, tighten to 175 Nm (129 lb-ft). All vehicles except hybrid 14. Remove the rear transaxle support isolator through bolt. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 6863 - To install, tighten to 115 Nm (85 lb-ft). All vehicles 15. Remove the power steering coupler bolt. Discard the bolt. - To install, tighten to 63Nm (46 lb-ft). 16. Remove the 2 outer tie-rod end nuts. Discard the nuts. - To install, tighten to 55 Nm (41 lb-ft). 17. Using the Tie-Rod End Remover, separate the tie rod from the wheel knuckle. 18. NOTE: Use the hex-holding fixture to prevent the ball stud from turning while removing and installing the stabilizer link nut. Remove the 2 lower stabilizer bar link nuts. Discard the nuts. To install, tighten to 55 Nm (41 lb-ft). 19. Remove the 2 lower control arm ball joint pinch bolt nuts and pinch bolts. Discard the nuts and the bolts. - To install, tighten to 63 Nm (46 lb-ft). 20. Using a suitable lift, support the front subframe. 21. NOTE: - Do not allow the front subframe rear bolts to come out of the lower control arm bushing. - When installing the front subframe rear bolts, make sure both of the front subframe rear bolts are fully engaged in their cage nuts before tightening to specification. Loosen the 2 front subframe rear bolts. To install, tighten to 175 Nm (129 lb-ft). 22. Remove the 2 front subframe nuts. - To install, tighten to 150 Nm (111 lb-ft). 23. 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 front subframe. 24. To install, reverse the removal procedure. - Transfer the components as necessary. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > Customer Interest: > 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > Customer Interest: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 6872 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > Customer Interest: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 6873 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 (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) 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 6879 (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 (L4-2.5L Hybrid (2009)) 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 6880 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Subframe Mount: > 09-11-9 > Jun > 09 > Navigation Radio - Time Displays Twice In CD Mode Entertainment System Control Module: All Technical Service Bulletins Navigation Radio - Time Displays Twice In CD Mode TSB 09-11-9 06/15/09 NAVIGATION RADIO - WHEN ON IN CD MODE - TIME DISPLAYS TWICE IN THE FDIM FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape and Mariner vehicles equipped with Navigation radio, may exhibit a concern when turning on the audio unit in CD mode. The time will display twice in the Front Display lnter[ace Module (FDIM), both in the center and in the upper right hand corner. Normal operation should be the time displaying in the center of the FDIM when the Navigation unit is off and in the upper right hand corner of the FDIM when the Navigation unit is on. ACTION Reprogram the Front Display Interface Module (FDIM) module to the latest calibration using IDS release 61.04 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration and IDS patch files may also be obtained at the website. 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 091109A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Reprogram The FDIM (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 19C116 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Subframe Mount: > Page 6886 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Subframe Mount: > Page 6887 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Subframe Mount: > Page 6888 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Subframe Mount: > Page 6889 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Subframe Mount: > Page 6890 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Subframe Mount: > Page 6891 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Customer Interest: > 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Customer Interest: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 6900 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Customer Interest: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 6901 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 (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) 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 6907 (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 (L4-2.5L Hybrid (2009)) 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 6908 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe: > 10-13-2 > Jul > 10 > Steering - Steering Column Pop/Clunk On Turns Steering Shaft: All Technical Service Bulletins Steering - Steering Column Pop/Clunk On Turns TSB 10-13-2 07/19/10 STEERING COLUMN POP/CLUNK NOISE ON TURNS - BUILT ON OR BEFORE 6/11/2010 FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner This article supersedes TSB 09-22-18 to update the production fix date and Service Procedure. ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 6/11/2010 may exhibit a pop or clunk noise from the steering column area while turning. This noise typically occurs quarter turn before the steering wheel reaches it's end of travel stop and typically goes away with weight off the wheels. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FAILURE TO PERFORM STEERING WHEEL POSITION SENSOR CALIBRATION PROCEDURE, AFTER STEERING COLUMN REPLACEMENT, MAY RESULT IN STEERING COLUMN NOISE ON TURNS. 1. Verify noise is coming from steering column and/or steering shaft area and occurs before steering wheel reaches it's end of travel stop. a. If noise is only present when the steering wheel contacts end of travel stop, it is a normal characteristic of the vehicle and this procedure does not apply. b. If noise is present before or between steering wheel end of travel stop, proceed to Step 2. 2. Replace both the steering shaft and steering shaft coupling u-joint per online Workshop Manual (WSM), Section 211-04. a. Torque the steering column coupling-to-steering column shaft bolt to 52 lb-ft (70 N.m). 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 101302A 2008-2010 Escape, 0.9 Hr. Mariner: Replace The Steering Shaft And Coupling U-Joint Includes Time To Diagnose Concern (Do Not Use With Any Other Labor Operations) DEALER CODING Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe: > 10-13-2 > Jul > 10 > Steering - Steering Column Pop/Clunk On Turns > Page 6914 CONDITION BASIC PART NO. CODE 3B676 14 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe: > Page 6915 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe: > Page 6916 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe: > Page 6917 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe: > Page 6918 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe: > Page 6919 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe: > Page 6920 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 6921 Rear Subframe: Service and Repair SUBFRAME - REAR Subframe - Rear Removal All vehicles 1. NOTICE: Suspension and subframe fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. With the vehicle in NEUTRAL, position it on a hoist. Vehicles with all All-Wheel Drive (AWD) 2. Remove the rear axle assembly. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 6922 All vehicles 3. Remove the rear stabilizer bar link upper nuts. 4. Remove the 4 bolts and position the 4 rear control arms aside. 5. Remove and discard the exhaust hanger from the subframe. 6. With an assistant, remove the 4 bolts and the rear subframe. Installation All vehicles 1. With an assistant, position the rear subframe and install the bolts. - To install, tighten the rear bolts to 115 Nm (85 lb-ft). - To install, tighten the front bolts to 115 Nm (85 lb-ft). 2. Install a new exhaust hanger on the subframe. 3. NOTE: The vehicle must be at ride height before tightening the bolts. Position the 4 rear control arms into the subframe. Loosely install the bolts. 4. Install the rear stabilizer bar link upper nuts. - Tighten to 48 Nm (35 lb-ft). Vehicles with AWD 5. Install the rear axle assembly. All vehicles 6. Tighten the 4 rear control arms bolts. - Tighten to 115 Nm (85 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 6923 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > Customer Interest: > 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > Customer Interest: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 6932 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > Customer Interest: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 6933 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 (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) 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 6939 (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 (L4-2.5L Hybrid (2009)) 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 6940 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe Mount: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Catalytic Converter Mounting Gasket: All Technical Service Bulletins Engine Controls/Exhaust MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe Mount: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 6946 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe Mount: > Page 6947 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe Mount: > Page 6948 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe Mount: > Page 6949 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe Mount: > Page 6950 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe Mount: > Page 6951 (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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Subframe Mount: > Page 6952 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Customer Interest for Grille: > 09-26-12 > Jan > 10 > Body - Front Grille Chrome Peeling Grille: Customer Interest Body - Front Grille Chrome Peeling TSB 09-26-12 01/04/10 FRONT GRILLE - CHROME PEEL FORD: 2008-2009 Escape ISSUE Some 2008-2009 Escape and Escape Hybrid vehicles may exhibit chrome peel appearance at the base of the front grille stanchion. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE If vehicle exhibits front grille chrome peel at the base of the stanchions, as specified in photo, with no evidence of impact damage, then replace the affected front grille(s). (Figure 1) Replace Only The Radiator Grille: 1. Remove the two (2) upper grille bolts. (Figure 2-A) 2. Slightly tip the grille outward and remove the two (2) lower inside grille bolts. (Figure 2-B) 3. Slightly tip the grille outward and remove the two (2) lower grille speed nuts that attach the grille to the front bumper cover. (Figure 2-C) 4. Release the three (3) lower grille retainers from the upper bumper cover. (Figure 2-D) 5. Remove the radiator grille. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Customer Interest for Grille: > 09-26-12 > Jan > 10 > Body - Front Grille Chrome Peeling > Page 6961 6. Install the new radiator grille and attach the three (3) lower grille retainers to the upper bumper cover by pushing the grille into the upper bumper cover. Make sure that all three (3) grille retainers make an audible click when attaching to the upper bumper cover. 7. Hand-tighten the two (2) lower grille speed nuts until the speed nuts are snug. 8. Hand-tighten the two (2) lower inside grille bolts until the bolts are snug. 9. Tighten the two (2) upper grille bolts to 71 lb-in (8 N.m). Replace Both Grilles Or Bumper Grille Only: 1. Refer to Workshop Manual (WSM), Section 501-19 to remove the bumper cover. 2. Refer to WSM, Section 501-08 to remove radiator grille from bumper cover. 3. Place the bumper cover assembly on a clean work bench on top of a fender cover to prevent scratching of the paint. 4. Push out the six top retainer snap tabs. (Figure 3-A) 5. Remove the passenger side push pin using a flat screwdriver. (Figure 3-B) 6. Position aside the wiring harness. 7. Push out the three (3) lower valance panel retainer tabs. (Figure 3-C) 8. Using end cutting pliers or equivalent, cut off the four (4) retainer snap tabs while being careful not to damage the outer bumper cover. (Figures 3-D and 4) NOTE DO NOT ATTEMPT TO PRY BUMPER SLOTS OPEN TO RELEASE THE TABS AS THIS WILL RESULT IN VISIBLE DAMAGE TO THE OUTER BUMPER COVER. 9. Remove and discard old bumper grille from bumper cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Customer Interest for Grille: > 09-26-12 > Jan > 10 > Body - Front Grille Chrome Peeling > Page 6962 10. Position the new bumper grille on the bumper cover slots and push in to engage the snap tabs. 11. Install the lower push pin. 12. Re-position wiring harness. 13. Install radiator grille to bumper cover, refer to WSM, Section 501-08. 14. Install the bumper cover assembly, refer to WSM section 501-19. Parts Block 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 092612A 2008-2009 Escape: 0.3 Hr. Replace The Radiator Grille Following The Service Procedure (Do Not Use With Any Other Labor Operations) 092612B 2008-2009 Escape: 0.8 Hr. Replace The Bumper Grille And The Radiator Grille If Necessary Following The Service Procedure Includes Time To Remove And Install The Bumper Cover (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 8150 34 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grille: > 09-26-12 > Jan > 10 > Body - Front Grille Chrome Peeling Grille: All Technical Service Bulletins Body - Front Grille Chrome Peeling TSB 09-26-12 01/04/10 FRONT GRILLE - CHROME PEEL FORD: 2008-2009 Escape ISSUE Some 2008-2009 Escape and Escape Hybrid vehicles may exhibit chrome peel appearance at the base of the front grille stanchion. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE If vehicle exhibits front grille chrome peel at the base of the stanchions, as specified in photo, with no evidence of impact damage, then replace the affected front grille(s). (Figure 1) Replace Only The Radiator Grille: 1. Remove the two (2) upper grille bolts. (Figure 2-A) 2. Slightly tip the grille outward and remove the two (2) lower inside grille bolts. (Figure 2-B) 3. Slightly tip the grille outward and remove the two (2) lower grille speed nuts that attach the grille to the front bumper cover. (Figure 2-C) 4. Release the three (3) lower grille retainers from the upper bumper cover. (Figure 2-D) 5. Remove the radiator grille. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grille: > 09-26-12 > Jan > 10 > Body - Front Grille Chrome Peeling > Page 6968 6. Install the new radiator grille and attach the three (3) lower grille retainers to the upper bumper cover by pushing the grille into the upper bumper cover. Make sure that all three (3) grille retainers make an audible click when attaching to the upper bumper cover. 7. Hand-tighten the two (2) lower grille speed nuts until the speed nuts are snug. 8. Hand-tighten the two (2) lower inside grille bolts until the bolts are snug. 9. Tighten the two (2) upper grille bolts to 71 lb-in (8 N.m). Replace Both Grilles Or Bumper Grille Only: 1. Refer to Workshop Manual (WSM), Section 501-19 to remove the bumper cover. 2. Refer to WSM, Section 501-08 to remove radiator grille from bumper cover. 3. Place the bumper cover assembly on a clean work bench on top of a fender cover to prevent scratching of the paint. 4. Push out the six top retainer snap tabs. (Figure 3-A) 5. Remove the passenger side push pin using a flat screwdriver. (Figure 3-B) 6. Position aside the wiring harness. 7. Push out the three (3) lower valance panel retainer tabs. (Figure 3-C) 8. Using end cutting pliers or equivalent, cut off the four (4) retainer snap tabs while being careful not to damage the outer bumper cover. (Figures 3-D and 4) NOTE DO NOT ATTEMPT TO PRY BUMPER SLOTS OPEN TO RELEASE THE TABS AS THIS WILL RESULT IN VISIBLE DAMAGE TO THE OUTER BUMPER COVER. 9. Remove and discard old bumper grille from bumper cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grille: > 09-26-12 > Jan > 10 > Body - Front Grille Chrome Peeling > Page 6969 10. Position the new bumper grille on the bumper cover slots and push in to engage the snap tabs. 11. Install the lower push pin. 12. Re-position wiring harness. 13. Install radiator grille to bumper cover, refer to WSM, Section 501-08. 14. Install the bumper cover assembly, refer to WSM section 501-19. Parts Block 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 092612A 2008-2009 Escape: 0.3 Hr. Replace The Radiator Grille Following The Service Procedure (Do Not Use With Any Other Labor Operations) 092612B 2008-2009 Escape: 0.8 Hr. Replace The Bumper Grille And The Radiator Grille If Necessary Following The Service Procedure Includes Time To Remove And Install The Bumper Cover (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 8150 34 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Page 6970 Grille: Service and Repair Radiator Grille Removal and Installation All vehicles 1. Remove the front bumper cover. Escape only 2. Remove the 2 radiator grille-to-fascia screws. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Page 6971 3. Remove the 2 radiator grille pinch nuts. 4. Release the 3 radiator grille retaining clips and remove the radiator grille from the fascia. Mariner only 5. Push outward on the 12 radiator grille clips to release the radiator grille from the bumper cover and remove the radiator grille. All vehicles 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp Switch > Component Information > Service and Repair Console Lamp Switch: Service and Repair Ambient Lighting Switch Removal and Installation 1. Remove the floor console finish panel. - Disconnect the electrical connector. 2. Squeeze the retaining tabs and remove the ambient lighting switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering Supplemental Restraint System (SRS) Depowering and Repowering Depowering Procedure WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 OFF. 3. At the Smart Junction Box (SJB), located at the RH side of the center console, remove the cover and the RCM fuse 32 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition from OFF to ON. 2. Install RCM fuse 32 (10A) to the SJB and install the cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6982 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 4. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the 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 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6983 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 to OFF. 3. At the Smart Junction Box (SJB) located at the RH side of the center console, remove the cover and the RCM fuse 32 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Using a 3-mm Allen wrench or a suitable tool, place it in the driver air bag module release hole on the underside of the steering wheel. 8. NOTICE: During driver air bag module removal, make sure all 3 driver air bag module hooks are released from the steering wheel wire Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6984 clip. Failure to do so may cause damage to the driver air bag module and or the steering wheel. NOTE: The driver air bag module is removed for clarity. Position the 3-mm Allen wrench or suitable tool against the wire clip and push inward disengaging the wire clip from the 3 driver air bag module hooks. 9. Disconnect the horn electrical connector. Then disconnect the 2 driver air bag module electrical connectors and remove the driver air bag module. 10. Open and lower the glove compartment door. 11. Remove the 2 passenger air bag module bolts. 12. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Failure to follow this instruction may result in vehicle damage, equipment damage, component damage and/or system failure. NOTE: Use care when removing the passenger air bag module from the instrument panel. The passenger air bag module can drop down during removal and the passenger air bag module rear bracket can scratch the front of the instrument panel. Through the glove compartment opening, release the passenger air bag module deployment door clips while pushing the passenger air bag module out of the instrument panel. 13. Remove the passenger air bag module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6985 1. Disconnect the 2 passenger air bag module electrical connectors. 2. Detach the wire harness routing clip and remove the passenger air bag module. 14. From under the rear of the passenger seat, slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 15. Remove the passenger side D-pillar trim panel. 1. Separate the weatherstrip. 2. Pull out and separate the quarter trim panel at the D-pillar trim panel. 3. Pull out to release the retainers and remove the D-pillar trim panel. 16. Disconnect the passenger side safety canopy module electrical connector. 17. Remove the driver side D-pillar trim panel. 1. Separate the weatherstrip. 2. Pull out and separate the quarter trim panel at the D-pillar trim panel. 3. Pull out to release the retainers and remove the D-pillar trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6986 18. Disconnect the driver side safety canopy module electrical connector. 19. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 20. Install RCM fuse 32 (10A) to the SJB. 21. Connect the battery ground cable. Reactivation 1. Remove RCM fuse 32 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 4. Connect the driver side safety canopy module electrical connector. 5. Install the driver side D-pillar trim panel. 1. Engage the D-pillar trim panel to the quarter trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6987 2. Install the D-pillar trim panel. 3. Install the weatherstrip. 6. Connect the passenger side safety canopy module electrical connector. 7. Install the passenger side D-pillar trim panel. 1. Engage the D-pillar trim panel to the quarter trim panel. 2. Install the D-pillar trim panel. 3. Install the weatherstrip. 8. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 9. NOTICE: During passenger air bag module installation, make sure the passenger air bag module wire harness routing clip is attached to the passenger air bag module. Failure to follow this instruction may result in wiring harness damage. NOTICE: The passenger air bag module electrical connectors are unique and cannot be reversed when connected to the passenger air bag module. Match the electrical connector key to the keyway in the passenger air bag module. Do not force the electrical connectors into the passenger air bag module. Failure to follow these instructions may result in component and/or connector damage. Install the passenger air bag module. 1. Connect the 2 passenger air bag module electrical connectors. 2. Attach the wire harness routing clip. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6988 10. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Failure to follow this instruction may result in vehicle damage, equipment damage, component damage and/or system failure. NOTE: During passenger air bag module installation, make sure all the deployment door clips are fully seated into the instrument panel. NOTE: Use care when installing the passenger air bag module in the instrument panel. The passenger air bag module rear bracket can scratch the front of the instrument panel. Position the passenger air bag module and seat the passenger air bag module deployment door clips into the instrument panel. 11. Install the 2 passenger air bag module bolts. - To install, tighten to 8 Nm (71 lb-in). 12. Close the glove compartment door. 13. Install the driver air bag module electrical connectors fully into the driver air bag module. Then connect the horn electrical connector. 14. NOTE: Make sure the driver air bag module wiring harness is routed down and away from the driver air bag module hooks during installation. NOTE: Audible clicks will be heard when the 3 wire clips are seated in the 3 driver air bag module hooks. Align the driver air bag module hooks to the steering wheel and, while pushing inward, seat the 3 driver air bag module hooks to the steering wheel wire clip. - When the 3 driver air bag module hooks are seated in place, gently pull outward at the corners of the driver air bag module to make sure that the 3 hooks are fully seated. There should also be an even gap between the driver air bag module trim cover and the steering wheel. Check the driver air bag module and trim cover for correct movement when applying the horn. 15. Turn the ignition switch from OFF to ON. 16. Install RCM fuse 32 (10A) to the SJB and install the cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6989 17. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 18. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair Headliner Removal and Installation 1. Remove the LH and RH A-pillar trim panels. For additional information, refer to A-Pillar Trim Panel See: Trim Panel/Service and Repair/A-Pillar Trim Panel. 2. Remove the LH and RH B-pillar trim panels. For additional information, refer to B-Pillar Trim Panel See: Trim Panel/Service and Repair/B-Pillar Trim Panel. 3. Remove the LH and RH C-pillar trim panels. For additional information, refer to C-Pillar Trim Panel See: Trim Panel/Service and Repair/C-Pillar Trim Panel. 4. Remove the LH and RH D-pillar trim panels. For additional information, refer to D-Pillar Trim Panel See: Trim Panel/Service and Repair/D-Pillar Trim Panel. 5. Open the overhead console door. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 6993 6. Remove the 2 screws and the overhead console. - Disconnect the electrical connector. 7. Remove the LH and RH sun visors. - If equipped, disconnect the electrical connectors. 8. NOTE: Do not fully remove the retaining screws from the sun visor clips. Remove the LH and RH sun visor clips. - Partially remove the retaining screws from the sun visor clips. - Pull downward on the sun visor clips to remove them from the headliner. 9. Using a small flat screwdriver, release and remove the interior lamp lens. 10. Remove the interior lamp. - Early build, remove the 2 screws. - Late build, remove the 2 pushpins. - Disconnect the electrical connector. 11. Remove the cargo lamp. - Disconnect the electrical connector. 12. Remove the 3 child seat tether anchor covers. 13. Remove the 3 bolts and the child seat tether anchors. - To install, tighten to 22 Nm (16 lb-ft). 14. If equipped, remove the screw and the garment hook. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 6994 - Open the garment hook screw cover. - Remove the garment hook screw. To install, tighten to 7 Nm (62 lb-in). 15. NOTE: When installing the headliner trim ring, it should meet at the rear of the roof opening and have no gaps or overlaps. If equipped, remove the headliner trim ring. 16. Remove the 5 headliner pin-type retainers. 17. Remove the headliner. 18. To install, reverse the removal procedure. - Transfer parts as necessary. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View Trim Panel: Service and Repair Interior Trim - Exploded View Interior Trim - Exploded View Early Build Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 6999 Late Build Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7000 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7001 Trim Panel: Service and Repair A-Pillar Trim Panel A-Pillar Trim Panel Removal All trim panels 1. Position the LH or RH front door weatherstrips aside. Passenger side only 2. Remove the A-pillar assist handle screw covers. 3. Remove the A-pillar assist handle screws and remove the assist handle. All trim panels 4. Pull inward on the upper A-pillar trim panel to release the A-pillar trim panel retaining clips. Driver side only 5. NOTE: Remove the A-pillar tether clip from the A-pillar trim panel. Do not remove the A-pillar tether clip from the A-pillar unless a new tether is being installed. Remove the A-pillar tether clip from the A-pillar trim panel. - Insert a flat-blade screwdriver into the base of the A-pillar tether clip. - Apply downward pressure on the screwdriver, sliding the A-pillar tether clip base downwards. All trim panels 6. Remove the A-pillar trim panel. Installation All trim panels 1. Install the lower A-pillar trim panel into the instrument panel. Driver side only 2. WARNING: A new A-pillar trim panel tether must be installed if the tether is damaged or does not fasten correctly. During a side air curtain deployment the A-pillar trim panel tether helps prevent the trim from striking the occupant. Failure to follow this instruction may result in serious injury to vehicle occupant(s). Install the A-pillar tether clip base onto the A-pillar trim panel. Position the A-pillar tether clip base into the A-pillar tether holder located on the A-pillar trim panel. - Slide the A-pillar tether clip base upwards into the A-pillar tether holder until the tether is fully seated. 3. NOTICE: The A-pillar trim panel tether must be aligned correctly or damage to the tether will occur. NOTICE: To avoid damage to the A-pillar trim panel, remove any retaining clips from the body and attach them to the A-pillar trim panel before installing. NOTE: The A-pillar trim panel tether clip, located on the A-pillar, installs into the A-pillar trim panel tether base, located on the A-pillar trim panel. Install the A-pillar trim panel onto the A-pillar. Passenger side only Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7002 4. Install the A-pillar assist handle and install the screws. 5. Install the A-pillar assist handle screw covers. All trim panels 6. Install the LH or RH front door opening weatherstrips. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7003 Trim Panel: Service and Repair B-Pillar Trim Panel B-Pillar Trim Panel Removal and Installation Upper 1. NOTE: Inspect the safety belt D-ring cover for damage. If the safety belt D-ring cover does not remain in place, install a new cover. Remove the safety belt guide cover by squeezing the height adjuster buttons and pulling the cover out at the bottom. 2. Remove the safety belt bolt. - To install, tighten to 48 Nm (35 lb-ft). 3. Position the front and rear door opening weatherstrips aside. 4. NOTE: Lower the adjustable safety belt to access the B-pillar trim panel bolt. Remove the cover, bolt and the upper B-pillar trim panel. - To install, tighten to 7 Nm (62 lb-in). Lower 5. Remove the 2 pin-type retainers and the front door scuff plate trim panel. 6. Remove the 2 pin-type retainer and the rear door scuff plate trim panel. 7. Remove the lower B-pillar trim panel. All vehicles 8. NOTICE: To avoid damage to the B-pillar trim panel, remove any retaining clips from the body and attach them to the B-pillar trim panel before installing. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7004 Trim Panel: Service and Repair C-Pillar Trim Panel C-Pillar Trim Panel Removal and Installation Early and late build 1. NOTE: Inspect the safety belt D-ring cover for damage. If the safety belt D-ring cover does not remain in place, install a new cover. Remove the safety belt D-ring bolt cover. 2. Remove the safety belt bolt. - To install, tighten to 48 Nm (35 lb-ft). 3. Remove the quarter trim panel. For additional information, refer to Quarter Trim Panel . 4. Position the rear door weatherstrip aside. Early build 5. NOTICE: To avoid damage to the C-pillar trim panel, remove any retaining clips from the body and attach them to the C-pillar trim panel before installing. Remove the cover, the bolt and the C-pillar trim panel. - To install, tighten to 7 Nm (62 lb-in). Late build 6. Release the C-pillar coat hook by inserting a small flat screwdriver in the slot at the base of the coat hook. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7005 7. Remove the coat hook. - LH coat hook, twist clockwise. - RH coat hook, twist counterclockwise. 8. Remove the C-pillar trim panel bolt. - To install, tighten to 7 Nm (62 lb-in). Early and late build 9. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7006 Trim Panel: Service and Repair D-Pillar Trim Panel D-Pillar Trim Panel Removal and Installation 1. Remove the quarter trim panel. For additional information, refer to Quarter Trim Panel . 2. NOTICE: To avoid damage to the D-pillar trim panel, remove any retaining clips from the body and attach them to the D-pillar trim panel before installing. Remove the D-pillar trim panel by pulling straight outward to release the retaining clips. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair Utility Storage Compartment: Service and Repair Instrument Panel - Exploded View Instrument Panel Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Page 7010 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair Door Lock Cylinder Removal and Installation NOTE: Individual door lock cylinders are repaired by discarding the inoperative door lock cylinder and building a new door lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new door lock cylinder to the current key code of the vehicle. 1. Remove the exterior front door handle reinforcement. For additional information, refer to Door Handle Reinforcement - Exterior, Front See: Doors, Hood and Trunk/Doors/Front Door/Front Door Handle/Front Door Exterior Handle/Service and Repair/Door Handle Reinforcement - Exterior, Front. 2. Remove the door lock cylinder. 1. Release the clips. 2. Remove the door lock cylinder. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment Key: Testing and Inspection Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment NOTE: This procedure is used when a customer needs keys programmed into the system and does not have 2 programmed ignition keys available. This procedure is also useful when a programmed ignition key(s) is lost or the ignition lock cylinder is replaced, and it is desired to erase key code(s) from the Passive Anti-Theft System (PATS) memory. NOTE: This procedure erases all programmed ignition keys from the vehicle memory and the vehicle does not start until 2 keys are programmed to the vehicle. This procedure also erases the Integrated Keyhead Transmitter (IKT) identification codes (TICs) from the Smart Junction Box (SJB), preventing the erased IKT from operating the Remote Keyless Entry (RKE) functions on the vehicle. NOTE: A minimum of 2 PATS keys must be programmed into the Instrument Cluster (IC) before the vehicle starts. NOTE: Two PATS encoded (contains a transponder) IKT keys (or standard PATS keys) with the correct mechanical cut must be available to carry out this procedure. One or both of them can be the customer's original keys. One or both of them can be an IKT or a standard PATS key. NOTE: If additional keys are to be programmed, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If the remaining keys are with the customer and are not available with the vehicle, instruct the customer to refer to the Owner's Literature for instructions on programming the remaining keys. In this case, the IC PID SPAREKEY must be enabled. NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. 1. Turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. From the scan tool menu select: IGNITION KEY CODE ERASE. Follow all Integrated Diagnostic System (IDS) screen instructions until the key erase procedure completes. The scan tool also instructs to program 2 keys to complete the process. 4. Turn the key to the OFF position and disconnect the scan tool (the key does not need to be removed at this time). 5. NOTE: The RKE data transfer takes place between the key and the IC first. After both keys are programmed into the IC, then the RKE data transfers from the IC to the Smart Junction Box (SJB). Until the final data transfer takes place into the SJB, the RKE functions does not operate. NOTE: IKT keys require a 6-second programming time frame for the RKE data transfer to take place, while standard PATS keys only require a minimum of 3 seconds. Turn the first PATS key to the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 7. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 8. The vehicle should now start with both ignition keys and the RKE transmitter portion of an IKT should function. 9. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the IC), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7020 Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7021 Key: Testing and Inspection Key Programming Switch State Control Key Programming Switch State Control NOTE: The spare key programming switch is a programmable switch which provides the capability to enable/disable the normal customer spare key programming procedure detailed in the Owner's Literature. It must read ENABLE if more than 2 keys need to be programmed into the Instrument Cluster (IC). For additional information, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. This programmable switch is provided as a convenience for rental company fleets or other fleet purchasers who may not want the spare key programming procedure available to the vehicle driver. NOTE: The spare key programming switch state can be viewed with the IC SPAREKEY PID. NOTE: If the SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the IC using Key Programming Using Two Programmed Keys. If the SPAREKEY PID reads DISABLED, the Key Programming Using Two Programmed Keys procedure does not function. This switch is set to ENABLE when the vehicle is built. This PID only affects the Key Programming Using Two Programmed Keys procedure. 1. Insert a programmed Passive Anti-Theft System (PATS) key (or Integrated Keyhead Transmitter (IKT)) into the ignition lock cylinder and turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. NOTE: The default setting on delivery of all new vehicles is ENABLED, when viewing the IC SPAREKEY PID. From the scan tool menu select: CUSTOMER SPARE KEY PROGRAMMING ENABLE and follow the Integrated Diagnostic System (IDS) on-screen instructions in order to complete the procedure. CUSTOMER SPARE KEY PROGRAMMING ENABLE - spare key programming procedure is accessible. - CUSTOMER SPARE KEY PROGRAMMING DISABLE - spare key programming procedure is not accessible. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7022 Key: Testing and Inspection Key Programming Using Two Programmed Keys Key Programming Using Two Programmed Keys NOTE: This procedure works only if 2 or more programmed ignition keys (they do not have to be Integrated Keyhead Transmitter (IKT) keys) are present. If 2 programmed Passive Anti-Theft System (PATS) keys are not available, refer to Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment. NOTE: The PID SPAREKEY must be enabled for this procedure to operate. If this PID is not enabled, refer to Key Programming Switch State Control See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Switch State Control, in order to enable the customer spare key programming PID. The PID SPAREKEY is set to ENABLE when the vehicle is built. NOTE: If the programming procedure is successful, the new key(s) starts the vehicle and the anti-theft indicator proves-out for approximately 3 seconds. If the programming procedure is not successful and the new key(s) does not start the engine, leave the key in the ON position for at least 3 seconds, then turn the key off. Repeat the key programming procedure from Step 1. If the failure repeats, refer to Anti-Theft See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection in the Diagnosis and Testing to review the DTCs and carry out the appropriate pinpoint tests. NOTE: A minimum of 2 PATS keys must be programmed into the Instrument Cluster (IC) before the vehicle will start. NOTE: If the vehicle is in unlimited key mode, this spare key programming procedure still functions. Any 2 keys that can start the vehicle can be used to program an additional unlimited key. NOTE: If additional keys are to be programmed, and the remaining keys are with the customer, or are not available, instruct the customer to refer to the Owner's Literature for instructions on programming the remaining keys. In this case, the PID SPAREKEY must be enabled. NOTE: If the steps are not carried out as outlined, the programming procedure ends. NOTE: Ignition keys must have a correct mechanical key cut for the vehicle and must be PATS encoded keys (contain a transponder). The key does not have to be an IKT key. NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. NOTE: A maximum of 8 ignition keys can be programmed to a PATS vehicle, of which up to 4 can be IKTs. If an attempt to program more than 4 IKTs occurs, the Smart Junction Box (SJB) and the IC set a memory full DTC (B1138), and the additional IKTs will not have any Remote Keyless Entry (RKE) function capability. If the vehicle is equipped with a message center, the IC displays the message INT KEY COULD NOT PROGRAM. The PATS portion of the additional key will function, but the RKE transmitter function will be inoperative. NOTE: When in the unlimited key mode (after the first 2 keys have been programmed to the vehicle), the N_KEYCODE PID will always read 2, no matter how many keys are programmed to the vehicle. 1. Insert a programmed ignition key (can be an IKT or a standard PATS key) into the ignition lock cylinder and turn the key from the OFF position to the ON position. 2. Leave the key in the ON position for 3 seconds, but not longer than 10 seconds. 3. Turn the key to the OFF position and remove the first key. 4. Within 10 seconds of turning the key to the OFF position, insert a second programmed ignition key (can be an IKT or a standard PATS key) into the ignition lock cylinder and turn the key from the OFF position to the ON position. 5. Leave the key in the ON position for 3 seconds, but not longer than 10 seconds. 6. Turn the key to the OFF position and remove the second key. 7. Within 20 seconds of turning the key to the OFF position, insert the unprogrammed ignition key (new PATS or IKT key) into the ignition lock cylinder and turn the key from the OFF position to the ON position. Leave the key in the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place, if programming an IKT key). 8. NOTE: The new key will now start the vehicle and will also operate the RKE functions, if there are 4 or fewer IKT keys programmed to the vehicle. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7023 Start the vehicle with the new key. If it is an IKT key, verify the RKE functions. 9. If additional programmed keys are desired, repeat Steps 1-7. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7024 Key: Testing and Inspection Spare Key Programming - Unlimited Key Mode Spare Key Programming - Unlimited Key Mode Enabling Unlimited Key Mode NOTE: Unlimited key mode is intended for use by those customers who need more than 8 keys for their vehicle. NOTE: If unlimited key mode is enabled, a maximum of 4 Integrated Keyhead Transmitter (IKT) keys can be programmed to the vehicle for Remote Keyless Entry (RKE) functionality. If more keys are required, they should be standard Passive Anti-Theft System (PATS) keys. If more than 4 IKT keys are programmed to the vehicle, the Smart Junction Box (SJB) and the Instrument Cluster (IC) will set DTC B1138 (memory full) and only 4 IKT keys will have RKE functionality, however, all of them will start the vehicle, if programmed correctly. NOTE: Before programming, the new key(s) must have the correct mechanical cut for the ignition lock cylinder. NOTE: The unlimited key mode is set up by creating a special, unique unlimited transponder security key code and programming this key code into all of the vehicle keys so they contain the same key code. NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2, no matter how many keys are programmed to the vehicle (after the first 2 keys have been programmed). 1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be programmed to all of their vehicles. All customer vehicles need to use the same number. Valid digits are 0-9 and the letters A-F. 2. NOTE: If the PID UNL_KEY_ID is not available, unlimited key mode is turned on and must be turned off before viewing the stored code. At this time, unlimited keys can be programmed to the vehicle. To view/change the stored code, follow the procedure for disabling the unlimited key mode below. Monitor the PID UNL_KEY_ID and compare its value against the code chosen in Step 1. It should not be the same key code. 3. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the Integrated Diagnostic System (IDS) on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 4. Once in security access, select: "program unlimited key code" and follow the IDS on-screen instructions. Enter the 8-digit code chosen by the customer in Step 1 of this procedure and follow the IDS on-screen instructions. 5. Select: "unlimited key mode ON" and follow the IDS on-screen instructions. 6. Select: "Ignition Key Code Erase" and follow the IDS on-screen instructions. 7. Disconnect the scan tool and turn the ignition switch to OFF. 8. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 9. Remove the first PATS key from the ignition lock cylinder. 10. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 11. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Disabling Unlimited Key Mode Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7025 NOTE: By disabling the unlimited key mode, the previous access code no longer operates the vehicle. 1. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 2. Select: "unlimited key mode OFF" and follow the IDS on-screen instructions. 3. Select: "Ignition Key Code Erase" and follow the IDS on-screen instructions. 4. Disconnect the scan tool and turn the ignition switch to OFF. 5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 6. Remove the first PATS key from the ignition lock cylinder. 7. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 8. NOTE: With the unlimited key mode turned off, a maximum of 8 keys can be programmed into the IC using the Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys procedure. The PID SPAREKEY must be enabled. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. The PID SPAREKEY must be enabled. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7026 Key: Testing and Inspection Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment NOTE: This procedure is used when a customer needs keys programmed into the system and does not have 2 programmed ignition keys available. This procedure is also useful when a programmed ignition key(s) is lost or the ignition lock cylinder is replaced, and it is desired to erase key code(s) from the Passive Anti-Theft System (PATS) memory. NOTE: This procedure erases all programmed ignition keys from the vehicle memory and the vehicle does not start until 2 keys are programmed to the vehicle. This procedure also erases the Integrated Keyhead Transmitter (IKT) identification codes (TICs) from the Smart Junction Box (SJB), preventing the erased IKT from operating the Remote Keyless Entry (RKE) functions on the vehicle. NOTE: A minimum of 2 PATS keys must be programmed into the Instrument Cluster (IC) before the vehicle starts. NOTE: Two PATS encoded (contains a transponder) IKT keys (or standard PATS keys) with the correct mechanical cut must be available to carry out this procedure. One or both of them can be the customer's original keys. One or both of them can be an IKT or a standard PATS key. NOTE: If additional keys are to be programmed, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If the remaining keys are with the customer and are not available with the vehicle, instruct the customer to refer to the Owner's Literature for instructions on programming the remaining keys. In this case, the IC PID SPAREKEY must be enabled. NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. 1. Turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. From the scan tool menu select: IGNITION KEY CODE ERASE. Follow all Integrated Diagnostic System (IDS) screen instructions until the key erase procedure completes. The scan tool also instructs to program 2 keys to complete the process. 4. Turn the key to the OFF position and disconnect the scan tool (the key does not need to be removed at this time). 5. NOTE: The RKE data transfer takes place between the key and the IC first. After both keys are programmed into the IC, then the RKE data transfers from the IC to the Smart Junction Box (SJB). Until the final data transfer takes place into the SJB, the RKE functions does not operate. NOTE: IKT keys require a 6-second programming time frame for the RKE data transfer to take place, while standard PATS keys only require a minimum of 3 seconds. Turn the first PATS key to the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 7. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 8. The vehicle should now start with both ignition keys and the RKE transmitter portion of an IKT should function. 9. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the IC), refer to Key Programming Using Two Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7027 Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Key Programming Switch State Control Key Programming Switch State Control NOTE: The spare key programming switch is a programmable switch which provides the capability to enable/disable the normal customer spare key programming procedure detailed in the Owner's Literature. It must read ENABLE if more than 2 keys need to be programmed into the Instrument Cluster (IC). For additional information, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. This programmable switch is provided as a convenience for rental company fleets or other fleet purchasers who may not want the spare key programming procedure available to the vehicle driver. NOTE: The spare key programming switch state can be viewed with the IC SPAREKEY PID. NOTE: If the SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the IC using Key Programming Using Two Programmed Keys. If the SPAREKEY PID reads DISABLED, the Key Programming Using Two Programmed Keys procedure does not function. This switch is set to ENABLE when the vehicle is built. This PID only affects the Key Programming Using Two Programmed Keys procedure. 1. Insert a programmed Passive Anti-Theft System (PATS) key (or Integrated Keyhead Transmitter (IKT)) into the ignition lock cylinder and turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. NOTE: The default setting on delivery of all new vehicles is ENABLED, when viewing the IC SPAREKEY PID. From the scan tool menu select: CUSTOMER SPARE KEY PROGRAMMING ENABLE and follow the Integrated Diagnostic System (IDS) on-screen instructions in order to complete the procedure. CUSTOMER SPARE KEY PROGRAMMING ENABLE - spare key programming procedure is accessible. - CUSTOMER SPARE KEY PROGRAMMING DISABLE - spare key programming procedure is not accessible. Key Programming Using Two Programmed Keys Key Programming Using Two Programmed Keys NOTE: This procedure works only if 2 or more programmed ignition keys (they do not have to be Integrated Keyhead Transmitter (IKT) keys) are present. If 2 programmed Passive Anti-Theft System (PATS) keys are not available, refer to Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment. NOTE: The PID SPAREKEY must be enabled for this procedure to operate. If this PID is not enabled, refer to Key Programming Switch State Control See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Switch State Control, in order to enable the customer spare key programming PID. The PID SPAREKEY is set to ENABLE when the vehicle is built. NOTE: If the programming procedure is successful, the new key(s) starts the vehicle and the anti-theft indicator proves-out for approximately 3 seconds. If the programming procedure is not successful and the new key(s) does not start the engine, leave the key in the ON position for at least 3 seconds, then turn the key off. Repeat the key programming procedure from Step 1. If the failure repeats, refer to Anti-Theft See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection in the Diagnosis and Testing to review the DTCs and carry out the appropriate pinpoint tests. NOTE: A minimum of 2 PATS keys must be programmed into the Instrument Cluster (IC) before the vehicle will start. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7028 NOTE: If the vehicle is in unlimited key mode, this spare key programming procedure still functions. Any 2 keys that can start the vehicle can be used to program an additional unlimited key. NOTE: If additional keys are to be programmed, and the remaining keys are with the customer, or are not available, instruct the customer to refer to the Owner's Literature for instructions on programming the remaining keys. In this case, the PID SPAREKEY must be enabled. NOTE: If the steps are not carried out as outlined, the programming procedure ends. NOTE: Ignition keys must have a correct mechanical key cut for the vehicle and must be PATS encoded keys (contain a transponder). The key does not have to be an IKT key. NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. NOTE: A maximum of 8 ignition keys can be programmed to a PATS vehicle, of which up to 4 can be IKTs. If an attempt to program more than 4 IKTs occurs, the Smart Junction Box (SJB) and the IC set a memory full DTC (B1138), and the additional IKTs will not have any Remote Keyless Entry (RKE) function capability. If the vehicle is equipped with a message center, the IC displays the message INT KEY COULD NOT PROGRAM. The PATS portion of the additional key will function, but the RKE transmitter function will be inoperative. NOTE: When in the unlimited key mode (after the first 2 keys have been programmed to the vehicle), the N_KEYCODE PID will always read 2, no matter how many keys are programmed to the vehicle. 1. Insert a programmed ignition key (can be an IKT or a standard PATS key) into the ignition lock cylinder and turn the key from the OFF position to the ON position. 2. Leave the key in the ON position for 3 seconds, but not longer than 10 seconds. 3. Turn the key to the OFF position and remove the first key. 4. Within 10 seconds of turning the key to the OFF position, insert a second programmed ignition key (can be an IKT or a standard PATS key) into the ignition lock cylinder and turn the key from the OFF position to the ON position. 5. Leave the key in the ON position for 3 seconds, but not longer than 10 seconds. 6. Turn the key to the OFF position and remove the second key. 7. Within 20 seconds of turning the key to the OFF position, insert the unprogrammed ignition key (new PATS or IKT key) into the ignition lock cylinder and turn the key from the OFF position to the ON position. Leave the key in the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place, if programming an IKT key). 8. NOTE: The new key will now start the vehicle and will also operate the RKE functions, if there are 4 or fewer IKT keys programmed to the vehicle. Start the vehicle with the new key. If it is an IKT key, verify the RKE functions. 9. If additional programmed keys are desired, repeat Steps 1-7. Spare Key Programming - Unlimited Key Mode Spare Key Programming - Unlimited Key Mode Enabling Unlimited Key Mode NOTE: Unlimited key mode is intended for use by those customers who need more than 8 keys for their vehicle. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7029 NOTE: If unlimited key mode is enabled, a maximum of 4 Integrated Keyhead Transmitter (IKT) keys can be programmed to the vehicle for Remote Keyless Entry (RKE) functionality. If more keys are required, they should be standard Passive Anti-Theft System (PATS) keys. If more than 4 IKT keys are programmed to the vehicle, the Smart Junction Box (SJB) and the Instrument Cluster (IC) will set DTC B1138 (memory full) and only 4 IKT keys will have RKE functionality, however, all of them will start the vehicle, if programmed correctly. NOTE: Before programming, the new key(s) must have the correct mechanical cut for the ignition lock cylinder. NOTE: The unlimited key mode is set up by creating a special, unique unlimited transponder security key code and programming this key code into all of the vehicle keys so they contain the same key code. NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2, no matter how many keys are programmed to the vehicle (after the first 2 keys have been programmed). 1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be programmed to all of their vehicles. All customer vehicles need to use the same number. Valid digits are 0-9 and the letters A-F. 2. NOTE: If the PID UNL_KEY_ID is not available, unlimited key mode is turned on and must be turned off before viewing the stored code. At this time, unlimited keys can be programmed to the vehicle. To view/change the stored code, follow the procedure for disabling the unlimited key mode below. Monitor the PID UNL_KEY_ID and compare its value against the code chosen in Step 1. It should not be the same key code. 3. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the Integrated Diagnostic System (IDS) on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 4. Once in security access, select: "program unlimited key code" and follow the IDS on-screen instructions. Enter the 8-digit code chosen by the customer in Step 1 of this procedure and follow the IDS on-screen instructions. 5. Select: "unlimited key mode ON" and follow the IDS on-screen instructions. 6. Select: "Ignition Key Code Erase" and follow the IDS on-screen instructions. 7. Disconnect the scan tool and turn the ignition switch to OFF. 8. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 9. Remove the first PATS key from the ignition lock cylinder. 10. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 11. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Disabling Unlimited Key Mode NOTE: By disabling the unlimited key mode, the previous access code no longer operates the vehicle. 1. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 2. Select: "unlimited key mode OFF" and follow the IDS on-screen instructions. 3. Select: "Ignition Key Code Erase" and follow the IDS on-screen instructions. 4. Disconnect the scan tool and turn the ignition switch to OFF. 5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 6. Remove the first PATS key from the ignition lock cylinder. 7. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7030 8. NOTE: With the unlimited key mode turned off, a maximum of 8 keys can be programmed into the IC using the Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys procedure. The PID SPAREKEY must be enabled. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. The PID SPAREKEY must be enabled. Spare Key Programming - Using Diagnostic Equipment Spare Key Programming - Using Diagnostic Equipment NOTE: This procedure is used when a customer needs to have an additional key programmed into the vehicle without erasing stored key codes, but does not have 2 programmed keys available. This procedure is also useful when attempting to determine if an ignition key is defective, as a new key can be installed without erasing keys or without having 2 programmed keys available. NOTE: Before programming, the new key must have the correct mechanical cut for the ignition lock cylinder. NOTE: If 8 keys are already programmed, this procedure does not allow any more ignition keys to be programmed. The number of keys that are programmed into the Passive Anti-Theft System (PATS) can be determined by viewing the N_KEYCODE PID. 1. Turn the new key to be programmed from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. NOTE: Make sure the selection made is "Program additional ignition key". If the "Ignition Key Code Erase" selection is made, all of the keys will be erased from the system. From the scan tool menu select: "Program additional ignition key". 4. Turn the key to the OFF position and disconnect the scan tool. 5. Start the vehicle with the new PATS key. The vehicle will now start with the new PATS key and also with the original PATS keys. If it is an IKT key, verify the RKE functions (if there are 4 or fewer IKT keys programmed). Passive Anti-Theft System (PATS) Parameter Reset Passive Anti-Theft System (PATS) Parameter Reset NOTE: When using the IDS, the Instrument Cluster (IC) and the Transmission Control Module (TCM) parameters are reset at the same time. NOTE: Once security access has been granted, multiple security access commands should be executed (if necessary) prior to exiting the command menu. This avoids an additional security access procedure and the associated 10 minute time delay. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7031 NOTE: Repair all Battery Control Module (BCM) DTCs and make sure the high voltage disconnect is installed before carrying out a parameter reset. A parameter reset will not occur if the High Voltage Traction Battery (HVTB) is not working correctly. 1. Turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. From the scan tool, select: Parameter Reset and follow the on-screen instructions. 4. NOTE: If the IC was replaced, follow Steps 4-9. If the IC and the TCM were replaced, follow Steps 4-9. If only the TCM was replaced, the procedure is completed. NOTE: If steps 4-9 are followed, 2 keys must be present. From the scan tool, select: Ignition Key Code Erase and follow the on-screen instructions. 5. Turn the key to the OFF position and disconnect the scan tool. 6. NOTE: Integrated Keyhead Transmitter (IKT) keys require a 6-second programming time frame for the Remote Keyless Entry (RKE) data transfer to take place, while standard PATS keys only require a minimum of 3 seconds. Turn the key to the ON position for a minimum of 6 seconds (if it is an IKT key). 7. Remove the key and cycle the second key to the ON position for a minimum of 6 seconds (if it is an IKT key). 8. Both keys will now start the vehicle and will also operate the RKE functions of the vehicle (if they are IKT keys). 9. NOTE: The RKE data transfer will take place between the key and the IC first. After both keys are programmed into the IC, the RKE data will transfer from the IC to the Smart Junction Box (SJB). Until the final data transfer takes place into the SJB, the RKE functions will not operate. If more keys are required to be programmed, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 7036 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 7037 Keyless Entry Key-Pad: Testing and Inspection Keyless Entry Keypad Code Programming Programming a Personal Code NOTE: Up to 3 personal codes can be programmed. Once there are 3 personal programmed codes, any attempt to program additional codes will be unsuccessful. 1. Enter the permanent factory keyless entry keypad code. 2. Within 5 seconds, press the 1/2 button on the keypad. 3. Enter the new 5-digit personal keyless entry keypad code. Each number must be entered within 5 seconds of each other. 4. The doors will lock then unlock to confirm the new code is programmed. Erasing the Personal Codes 1. Enter the permanent factory keyless entry keypad code. 2. Within 5 seconds, press the 1/2 button on the keypad and release. 3. Within 5 seconds, press and hold the 1/2 button on the keypad for 2 seconds. 4. All personal codes are now erased and only the permanent factory keyless entry keypad code will work. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 7038 Keyless Entry Key-Pad: Service and Repair Keyless Entry Keypad Removal and Installation 1. Remove the LH front door trim panel. 2. Position the watershield aside. 3. Remove the keypad retaining clip. 4. Remove the keypad from the door. - Disconnect the electrical connector. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry (RKE) Transmitter Programming Remote Keyless Entry (RKE) Transmitter Programming NOTE: This procedure is for programming conventional keyfobs only. The Remote Keyless Entry (RKE) transmitter of the Integrated Keyhead Transmitter (IKT) is programmed automatically during the Passive Anti-Theft System (PATS) programming. For additional information, refer to Key Programming Using Two Programmed Keys or Integrated Keyhead Transmitter Key Programming Using Diagnostic Equipment in Antitheft and Alarm Systems to program the IKT. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment NOTE: All RKE transmitters must be programmed at the same time. NOTE: Do not apply the brake pedal during this sequencing, as doing so ends the sequence and the transmitters will not be programmed. 1. Electronically unlock the door locks using the door lock control switch. 2. Cycle the ignition switch from the OFF to the RUN position 8 times in rapid succession (within 10 seconds), with the eighth turn ending in RUN. If the module successfully enters program mode, it locks and then unlocks all the doors. 3. NOTE: If no action is taken within 20 seconds after a transmitter has been programmed, the programming sequence ends (the doors lock and unlock to confirm that programming is complete). Within 20 seconds, press any button on the RKE transmitter to be programmed. The doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position - 20 seconds have passed since entering programming mode or since the last RKE transmitter was programmed - The maximum number (4) of RKE transmitters have been programmed 5. Check the operation of the RKE transmitter. If the door locks do not respond for the programmed RKE transmitter(s), wait several seconds and press the button again. If the door locks still fail to respond, refer to Locks, Latches and Entry Systems See: Power Locks/Testing and Inspection. (Make sure that no more than the maximum number of RKE transmitters are attempted to be programmed.) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 7043 Keyless Entry Transmitter: Testing and Inspection Autolock and Auto-Unlock Programming Autolock and Auto-Unlock Programming Autolock Programming Using the Power Door Unlock/Lock Procedure NOTE: The autolock feature can be activated/deactivated independently of the auto-unlock feature. 1. NOTE: Prior to beginning this procedure, make sure that the anti-theft system is not armed, the ignition is in the OFF position, and all the vehicle doors, liftgate and liftgate glass are closed. Close all the doors, the liftgate and the liftgate glass. 2. Confirm that the ignition is in the OFF position. 3. NOTE: Steps 3 through 7 must be carried out within 30 seconds. Turn the ignition from OFF to ON. 4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition from ON to OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition from OFF to ON. The horn will chirp once to indicate the system is in the enable/disable mode. 8. Press the door lock control switch UNLOCK button once, then the LOCK button once to toggle the autolock feature ON/OFF. The horn will chirp once to indicate autolock is disabled. If the horn chirps twice (one short and one long chirp), the autolock feature has been enabled. 9. Turn the ignition to the OFF position to exit the enable/disable mode. The horn will chirp once to indicate the procedure is complete. Autolock Programming Using the Keyless Entry Keypad Procedure (If Equipped) 1. Turn the ignition to the OFF position. 2. Close all the doors, the liftgate and the liftgate glass. 3. Enter the 5-digit permanent entry code on the keyless entry keypad. 4. Within 5 seconds of entering the code, press and hold the 3/4 button on the keypad. While holding the 3/4 button, press the 7/8 button. 5. Release the 7/8 button, then release the 3/4 button. The horn will chirp once to indicate autolock is disabled. If the horn chirps twice (chirp followed by a honk), the autolock feature has been enabled. Autolock Programming Using the Message Center Procedure (If Equipped) 1. To disable/enable the autolock feature, select AUTOLOCK [ON] OFF from the SETUP control for the current display mode. 2. Press the RESET control to turn the autolock ON or OFF. Auto-Unlock Programming Using the Power Door Unlock/Lock Procedure NOTE: The auto-unlock feature can be activated/deactivated independently of the autolock feature. 1. NOTE: Prior to beginning this procedure, make sure that the anti-theft system is not armed, the ignition is in the OFF position, and all the vehicle doors, liftgate and liftgate glass are closed. Close all the doors, the liftgate and the liftgate glass. 2. Confirm that the ignition is in the OFF position. 3. NOTE: Steps 3 through 7 must be carried out within 30 seconds. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 7044 Turn the ignition from OFF to ON. 4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition from ON to OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition from OFF to ON. The horn will chirp once to indicate the system is in the enable/disable mode. 8. Press the door lock control switch LOCK button once, then the UNLOCK button once to toggle the auto-unlock feature ON/OFF. The horn will chirp once to indicate auto-unlock is disabled. If the horn chirps twice (one short and one long chirp), the auto-unlock feature has been enabled. 9. Turn the ignition to the OFF position to exit the enable/disable mode. The horn will chirp once to indicate the procedure is complete. Auto-Unlock Programming Using the Keyless Entry Keypad Procedure (If Equipped) 1. Turn the ignition to the OFF position. 2. Close all the doors, the liftgate and the liftgate glass. 3. Enter the 5-digit permanent entry code on the keyless entry keypad. 4. Within 5 seconds of entering the code, press and hold the 3/4 button on the keypad. While holding the 3/4 button, press and release the 7/8 button 2 times. 5. Release the 3/4 button. The horn will chirp once to indicate auto-unlock is disabled. If the horn chirps twice (chirp followed by a honk), the auto-unlock feature has been enabled. Auto-Unlock Programming Using the Message Center Procedure (If Equipped) 1. To disable/enable the auto-unlock feature, select AUTOUNLOCK [ON] OFF from the SETUP control for the current display mode. 2. Press the RESET control to turn the auto-unlock ON or OFF. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 7045 Keyless Entry Transmitter: Testing and Inspection Perimeter Lighting Feature Programming Perimeter Lighting Feature Programming Programming the Perimeter Lighting Feature Using the Door Lock Control Switch NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the ON position. 2. Press the unlock button on the door lock control switch 3 times. 3. Turn the ignition switch from the ON to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the ON position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The unlock button must be pressed twice within 5 seconds. Within 30 seconds of entering the programming mode, press the unlock button on the door lock control switch twice to enable/disable the perimeter lighting feature. The horn chirps once if the perimeter lighting is disabled or a chirp followed by a honk if the perimeter lighting is enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 7046 Keyless Entry Transmitter: Testing and Inspection Stepped Unlock Programming Stepped Unlock Programming 1. With the ignition switch in the OFF position, press the LOCK and UNLOCK buttons on the Remote Keyless Entry (RKE) transmitter simultaneously for 4 seconds. The turn signals flash twice to indicate the mode change. 2. Repeat Step 1 to enable/disable the stepped unlocking feature. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Left Rear Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Left Rear > Page 7052 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Unit, Driver Side Front Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Unit, Driver Side Front > Page 7055 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Unit, Driver Side Front > Page 7056 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Unit, Driver Side Front > Page 7057 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 7062 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 7065 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 7066 Power Door Lock Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 7067 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 7068 Power Door Lock Switch: Service and Repair Door Lock Control Switch NOTE: LH side shown, RH side similar. Removal and Installation 1. Remove the front interior door handle. For additional information, refer to Interior Door Handle Front See: Doors, Hood and Trunk/Doors/Front Door/Front Door Handle/Front Door Interior Handle/Service and Repair/Interior Door Handle Front. 2. Release the tabs and remove the door lock control switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock > System Information > Service and Repair Trunk / Liftgate Lock: Service and Repair Liftgate Handle, Lock and Latch - Exploded View 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > Customer Interest for Heated Element: > 10-5-3 > Mar > 10 > Body/Instruments - Exterior Heated Mirror Glass Cracking Heated Element: Customer Interest Body/Instruments - Exterior Heated Mirror Glass Cracking TSB 10-5-3 03/29/10 EXTERIOR HEATED REAR VIEW MIRROR GLASS CRACK WHEN MIRROR DEFROST IS POWERED ON-BUILT ON OR BEFORE 03/31/2009 FORD: 2008-2009 Escape MERCURY: 2008-2009 Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles built on or before 03/31/2009 and equipped with heated exterior rear view mirrors may exhibit a glass thermal stress crack when mirror defrost is powered on. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the exterior mirror glass only if there's no evidence of impact damage. (Figure 1) Refer to Workshop Manual, Section 501-09 for removal and installation. 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 100503A 2008-2009 Escape, 0.2 Hr. Mariner: Replace The Exterior Mirror Glass On One Side (Do Not Use With Any Other Labor Operations) 100503B 2008-2009 Escape, 0.3 Hr. Mariner: Replace The Exterior Mirror Glass On Both Sides (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > Customer Interest for Heated Element: > 10-5-3 > Mar > 10 > Body/Instruments - Exterior Heated Mirror Glass Cracking > Page 7081 BASIC PART NO. CODE 17K707 01 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Element: > 10-5-3 > Mar > 10 > Body/Instruments - Exterior Heated Mirror Glass Cracking Heated Element: All Technical Service Bulletins Body/Instruments - Exterior Heated Mirror Glass Cracking TSB 10-5-3 03/29/10 EXTERIOR HEATED REAR VIEW MIRROR GLASS CRACK WHEN MIRROR DEFROST IS POWERED ON-BUILT ON OR BEFORE 03/31/2009 FORD: 2008-2009 Escape MERCURY: 2008-2009 Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles built on or before 03/31/2009 and equipped with heated exterior rear view mirrors may exhibit a glass thermal stress crack when mirror defrost is powered on. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the exterior mirror glass only if there's no evidence of impact damage. (Figure 1) Refer to Workshop Manual, Section 501-09 for removal and installation. 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 100503A 2008-2009 Escape, 0.2 Hr. Mariner: Replace The Exterior Mirror Glass On One Side (Do Not Use With Any Other Labor Operations) 100503B 2008-2009 Escape, 0.3 Hr. Mariner: Replace The Exterior Mirror Glass On Both Sides (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Element: > 10-5-3 > Mar > 10 > Body/Instruments - Exterior Heated Mirror Glass Cracking > Page 7087 BASIC PART NO. CODE 17K707 01 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair Power Mirror Motor: Service and Repair Exterior Mirror Motor Removal and Installation 1. Remove the exterior mirror glass. For additional information, refer to Exterior Mirror Glass See: Service and Repair/Exterior Mirror Glass. 2. Remove the exterior mirror motor screw. 3. With a flat-blade tool, release the 3 exterior mirror motor tabs. 4. Remove the exterior mirror motor. - Disconnect the electrical connector. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7094 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7095 Power Mirror Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7096 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7097 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7098 Power Mirror Switch: Service and Repair Exterior Mirror Control Switch Removal and Installation 1. Remove the LH sail panel. - Disconnect the electrical connector. 2. Remove the exterior mirror control switch. - Press the 2 retaining tabs. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Radiator Support > Component Information > Locations Radiator Support: Locations Front Structure Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair Seat Heater Control Module: Service and Repair Seat - Exploded View, Front Seat Backrest - Front NOTE: Driver seat shown, passenger seat similar. Seat Cushion - Driver NOTE: Power seat track shown, manual seat track similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Page 7106 Seat Cushion - Front, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Page 7107 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Locations > Heated Seats Relay Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Locations > Heated Seats Relay > Page 7112 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams > Heated Seat Relay, Driver Seat Heater Relay: Diagrams Heated Seat Relay, Driver Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams > Heated Seat Relay, Driver > Page 7115 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams > Heated Seat Relay, Driver > Page 7116 Seat Heater Relay: Diagrams Heated Seat Relay, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams > Heated Seat Relay, Driver > Page 7117 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 7121 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Roof Opening Panel - Exploded View Sunroof / Moonroof Motor: Service and Repair Roof Opening Panel - Exploded View Roof Opening Panel - Exploded View 1. For additional information, refer to the individual procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7132 Sunroof / Moonroof Motor: Service and Repair Roof Opening Panel Motor Roof Opening Panel Motor Removal and Installation NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel system, including: whenever the roof opening panel motor has been removed from the roof panel system, the roof opening panel glass has been removed from the roof opening panel system, the roof opening panel assembly has been removed from the vehicle, a new roof opening panel motor has been installed, a new roof opening panel glass has been installed or a new roof opening panel assembly has been installed. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. 1. Remove the headliner. 2. Disconnect the roof opening panel motor electrical connector. 3. Remove the 3 roof opening panel motor screws and the roof opening panel motor. - To install, tighten to 8 Nm (71 lb-in). 4. To install, reverse the removal procedure. - Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Roof Opening Panel Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Roof Opening Panel Switch > Page 7137 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7138 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7139 Sunroof / Moonroof Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7140 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Roof Opening Panel - Exploded View Sunroof / Moonroof Track: Service and Repair Roof Opening Panel - Exploded View Roof Opening Panel - Exploded View 1. For additional information, refer to the individual procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7145 Sunroof / Moonroof Track: Service and Repair Trough Assembly Trough Assembly Removal and Installation NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel system, including: whenever the roof opening panel motor has been removed from the roof panel system, the roof opening panel glass has been removed from the roof opening panel system, the roof opening panel assembly has been removed from the vehicle, a new roof opening panel motor has been installed, a new roof opening panel glass has been installed or a new roof opening panel assembly has been installed. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. 1. Remove the roof opening panel glass. For additional information, refer to Roof Opening Panel Glass See: Sunroof / Moonroof Panel/Service and Repair/Roof Opening Panel Glass. 2. Remove the 2 roof opening panel drain channel screws and the drain channel. 3. To install, reverse the removal procedure. - Verify that the roof opening panel is centered and aligned before tightening the glass screws. For additional information, refer to Roof Opening Panel Alignment See: Adjustments. - Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Roof Opening Panel - Exploded View 1. For additional information, refer to the individual procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Roof Opening Panel - Exploded View Sunroof / Moonroof Frame: Service and Repair Roof Opening Panel - Exploded View Roof Opening Panel - Exploded View 1. For additional information, refer to the individual procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7153 Sunroof / Moonroof Frame: Service and Repair Roof Opening Panel Frame Roof Opening Panel Frame Removal and Installation NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel system, including: whenever the roof opening panel motor has been removed from the roof panel system, the roof opening panel glass has been removed from the roof opening panel system, the roof opening panel assembly has been removed from the vehicle, a new roof opening panel motor has been installed, a new roof opening panel glass has been installed or a new roof opening panel assembly has been installed. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. 1. Remove the headliner. 2. Disconnect the 4 roof opening panel drain hoses. 3. Release the wire harness locators. 4. Remove the 8 roof opening panel frame bolts and remove the roof opening panel frame. - To install tighten to 9 Nm (80 lb-in). 5. To install, reverse the removal procedure. - Verify that the roof opening panel glass is centered and aligned correctly. For additional information, refer to Roof Opening Panel Alignment See: Adjustments. - Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 7157 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel - Exploded View Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel - Exploded View Roof Opening Panel - Exploded View 1. For additional information, refer to the individual procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7162 Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Glass Roof Opening Panel Glass NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel system, including: whenever the roof opening panel motor has been removed from the roof panel system, the roof opening panel glass has been removed from the roof opening panel system, the roof opening panel assembly has been removed from the vehicle, a new roof opening panel motor has been installed, a new roof opening panel glass has been installed or a new roof opening panel assembly has been installed. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. 1. Position the roof opening panel to the CLOSED position. 2. Remove the 4 roof opening panel glass screws and the roof opening panel glass. - To install tighten to 5 Nm (44 lb-in). 3. To install, reverse the removal procedure. - Verify that the roof opening panel is centered and aligned before tightening the glass screws. For additional information, refer to Roof Opening Panel Alignment See: Adjustments. - Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7163 Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Shield Roof Opening Panel Shield Removal and Installation NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel system, including: whenever the roof opening panel motor has been removed from the roof panel system, the roof opening panel glass has been removed from the roof opening panel system, the roof opening panel assembly has been removed from the vehicle, a new roof opening panel motor has been installed, a new roof opening panel glass has been installed or a new roof opening panel assembly has been installed. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. 1. Remove the roof opening panel drain trough. For additional information, refer to Trough Assembly See: Sunroof / Moonroof Track/Service and Repair/Trough Assembly. 2. Slide the roof opening panel shield forward halfway. 3. Disengage the roof opening panel shield guide feet. - Lift the front portion of the roof opening panel shield upward at center until able to disengage one of the front guide feet. 4. With one of the guide feet released, carefully rotate the roof opening panel shield in a clockwise manner to disengage the remaining guide feet. 5. To install, reverse the removal procedure. - Verify that the roof opening panel is centered and aligned before tightening the glass screws. For additional information, refer to Roof Opening Panel Alignment See: Adjustments. - Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 7168 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 7169 Power Seat Motor: Service and Repair Seat - Exploded View, Front Seat Backrest - Front NOTE: Driver seat shown, passenger seat similar. Seat Cushion - Driver NOTE: Power seat track shown, manual seat track similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 7170 Seat Cushion - Front, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 7171 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 7175 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 7176 Power Seat Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 7177 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 7178 Power Seat Switch: Service and Repair Seat - Exploded View, Front Seat Backrest - Front NOTE: Driver seat shown, passenger seat similar. Seat Cushion - Driver NOTE: Power seat track shown, manual seat track similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 7179 Seat Cushion - Front, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 7180 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement Seat Back: Removal and Replacement Seat - Exploded View, Front Seat - Exploded View, Front Seat Backrest - Front NOTE: Driver seat shown, passenger seat similar. Seat Cushion - Driver NOTE: Power seat track shown, manual seat track similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7185 Seat Cushion - Front, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7186 1. For additional information, refer to the procedures. Seat Backrest - Front Seat Backrest - Front Removal and Installation Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7187 NOTE: If a side air bag deployment took place, a new seat back pad, trim cover and side air bag module and nuts must be installed. The seat back frame should be replaced if necessary. NOTE: For component identification and locations, refer to Seat - Exploded View, Front See: Service and Repair/Front Seats/Seat - Exploded View, Front. 1. Remove the seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. 2. Remove the recliner handle. 3. Remove the outboard side shield. - For passenger seat, remove the screw and slide the outboard side shield forward. Release the rear clip and push forward to release the front clip. - For driver seat, remove the 3 screws. If equipped, disconnect the seat control switch electrical connector. 4. Remove the inboard side shield. - For driver seat, remove the 2 inboard side shield screws. - For passenger seat, remove the screw and slide the side shield forward to release the front hook. 5. Remove the wiring harness tie strap and detach the side air bag wiring harness pin-type retainer from the safety belt buckle pretensioner. 6. Disconnect the side air bag module electrical connector and detach it from the seat track. - Detach the pin-type retainers and wiring harness from the seat cushion. 7. Remove the bolt and position aside the safety belt buckle pretensioner. - To install, tighten to 40 Nm (30 lb-ft). 8. If equipped, disconnect the backrest heater mat electrical connector. - Access the electrical connector by slightly pulling the wiring harness out from the backrest cover. 9. NOTICE: Make sure the side air bag module wiring harness is not pinched between the side air bag module and the mounting bracket. Damage to the wire harness may occur. Disconnect the side air bag module electrical connector. - Route the side air bag wiring harness from between the seat track and cushion frame. 10. Remove the 4 backrest-to-seat track bolts (power seat) or 3 remaining backrest-to-seat track bolts (manual seat) and backrest. - To install, tighten to 50 Nm (37 lb-ft). 11. To install, reverse the removal procedure. Rear Seat Backrest Seat Backrest - Rear Removal NOTE: The RH rear seat backrest (40 percent) must be removed prior to the LH rear seat backrest (60 percent). NOTE: For component identification and locations, refer to Seat - Exploded View, Rear See: Service and Repair/Rear Seat - Exploded View. Both rear seat backrests 1. Position both rear seat cushions forward. 2. Route the safety belt buckles from the elastic straps. 3. Remove the RH outboard backrest-to-floor bolt. LH rear seat backrest Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7188 4. Remove the center safety belt anchor bolt. 5. Remove the LH outboard backrest-to-floor bolt. Both rear seat backrests 6. Release and position both rear backrests downward. 7. Remove the 2 pin-type retainers and position the carpet aside. 8. Remove the bolt cover. 9. Remove the RH outboard backrest-to-floor nut, inboard backrest-to-floor nut and inboard backrest-to-floor bolt. 10. Lift and remove the RH rear seat backrest. LH rear seat backrest 11. Remove the LH outboard backrest-to-floor nut. 12. Lift and remove the LH rear seat backrest. Installation NOTE: The LH rear seat backrest (60 percent) must be installed prior to the RH rear seat backrest (40 percent). NOTE: The seat-to-floor fasteners must be tightened in the sequence described in this procedure. NOTE: Make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. LH rear seat backrest 1. Position the LH rear seat backrest in the vehicle. 2. Install the LH outboard backrest-to-floor nut. Do not tighten at this time. RH rear seat backrest 3. Position the RH rear seat backrest in the vehicle. 4. Install the inboard backrest-to-floor nut and inboard backrest-to-floor bolt. - Tighten to 40 Nm (30 lb-ft). 5. Install the bolt cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7189 6. Install the RH outboard backrest-to-floor nut. - Tighten to 40 Nm (30 lb-ft). Both rear seat backrests 7. Tighten the LH outboard backrest-to-floor nut. - Tighten to 40 Nm (30 lb-ft). 8. Position the carpet and install the 2 pin-type retainers. 9. Position upward and latch both rear backrests. 10. Install the LH outboard backrest-to-floor bolt. - Tighten to 40 Nm (30 lb-ft). 11. Install the center safety belt anchor bolt. - Tighten to 48 Nm (35 lb-ft). RH rear seat backrest 12. Install the RH outboard backrest-to-floor bolt. - Tighten to 40 Nm (30 lb-ft). 13. Route the safety belt buckles through the elastic straps. 14. Position both rear seat cushions in place. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7190 Seat Back: Overhaul Seat Backrest - Front Seat Backrest - Front NOTE: Driver seat shown, passenger similar. Disassembly WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. 1. Remove the seat backrest. For additional information, refer to Seat Backrest - Front See: Removal and Replacement/Front Seats/Seat Backrest - Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7191 Front. 2. Remove the seat backrest cover. For additional information, refer to Seat Backrest Cover - Front See: Seat Cover/Service and Repair/Front Seats/Seat Backrest Cover - Front. 3. Detach the 2 side air bag module wiring harness retainers. 4. Remove the 2 side air bag module nuts and side air bag module. 5. Remove the backrest foam pad. 6. If equipped, remove the lumbar assembly. - Remove the 2 screws and position aside the lumbar adjuster. - Release the lumbar assembly from the backrest frame wires and remove. Assembly WARNING: Before installing the seat side air bag module/deployment chute assembly: - Inspect the side air bag module and mounting surfaces for any damage or foreign material. - Remove any foreign material from the mounting surfaces of the deployment chute, the seat backrest frame mounting bracket and the air bag module cavity in the seat backrest foam pad. - Install new parts if damaged. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. WARNING: Inspect the seat side air bag module and mounting surfaces for any damage or foreign material before installing the seat side air bag module. If any damage is found, install new components. If any foreign material is found, remove it. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. WARNING: If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag material has been exposed, install a new seat side air bag module. Never try to repair the seat side air bag module. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. NOTICE: Make sure the side air bag module wiring harness is not pinched between the side air bag module and the mounting bracket. Damage to the wire harness may occur. 1. If equipped, install the lumbar assembly. - Install the lumbar assembly to the backrest frame wires. - Install the lumbar adjuster and 2 screws. 2. Install the side air bag module and 2 nuts to the backrest frame mounting bracket. - Tighten to 5 Nm (44 lb-in). 3. Attach the 2 side air bag module wiring harness retainers to the seat backrest frame. 4. Install the backrest foam pad to the backrest frame. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7192 5. Install the seat backrest cover. For additional information, refer to Seat Backrest Cover - Front See: Seat Cover/Service and Repair/Front Seats/Seat Backrest Cover - Front. 6. Install the seat backrest. For additional information, refer to Seat Backrest - Front See: Removal and Replacement/Front Seats/Seat Backrest Front. Seat Backrest - Rear Seat Backrest - Rear NOTE: LH (60 percent) shown, RH (40 percent) similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7193 Disassembly and Assembly Both rear seat backrests 1. Remove the seat backrest cover. For additional information, refer to Seat Backrest Cover - Rear See: Seat Cover/Service and Repair/Rear Seat Backrest Cover. 2. Remove the backrest foam pad from the backrest frame. Sixty percent seat backrest 3. Release the seat latch cable from the center safety belt retractor. - For installation, make sure the rear safety belt retractor is not in the Automatic Locking Retractor (ALR) mode after installation. For additional information, refer to Seat Belt Systems. 4. Remove the 2 nuts and safety belt guide. - To install, tighten to 40 Nm (30 lb-ft). 5. Remove the nut and center safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). Both rear seat backrests 6. Remove the 2 bolts and backrest latch. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7194 - To install, tighten to 40 Nm (30 lb-ft). 7. Remove the bolt and inboard pivot bracket. - To install, tighten to 50 Nm (37 lb-ft). 8. Remove the bolt and outboard pivot bracket. - To install, tighten to 50 Nm (37 lb-ft). 9. NOTE: Make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To assemble, reverse the disassembly procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 09-23-3 > Nov > 09 > Interior - White Stains On Cloth Seat Covers Seat Cover: Customer Interest Interior - White Stains On Cloth Seat Covers TSB 09-23-3 11/30/09 CLOTH SEAT STAINS WITH WHITE RING OUTLINE - BUILT ON OR BEFORE 5/14/2009 (EXCLUDES XLS) FORD: 2008-2009 Escape Hybrid, Escape ISSUE Some 2008-2009 Escape and Escape Hybrid vehicles (excludes Mariner) equipped with Cloth seats (excludes XLS) and built on or before 5/14/2009, may exhibit stains with a white ring outline around them. An updated seat cover is now available to reduce this specific type of staining. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Inspect the seat cover stain for a white ring outline. (Figure 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 09-23-3 > Nov > 09 > Interior - White Stains On Cloth Seat Covers > Page 7203 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 09-23-3 > Nov > 09 > Interior - White Stains On Cloth Seat Covers > Page 7204 2. If the white ring stain is present, then replace the seat cover with latest level part. (Figures 2-3) Refer to Workshop Manual (WSM), Section 501-10 Seating Disassembly and Assembly. NOTE ONLY APPLIES TO STAINS WITH WHITE RING OUTLINE. REFER TO WARRANTY AND POLICY MANUAL FOR ANY OTHER TYPE OF SEAT COVER STAINS. 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 09-23-3 > Nov > 09 > Interior - White Stains On Cloth Seat Covers > Page 7205 092303A 2008-2009 Escape, 0.9 Hr. Escape Hybrid: Replace The Left Front Seat Cushion Cover (This Labor Operation Can Be Claimed With D, E, F, G, H, J, Or K) 092303 2008-2009 Escape, 1.1 Hrs. Escape Hybrid: Replace The Right Front Seat Cushion Cover Includes Time To Reset The Occupant Classification Sensor (OCS) (This Labor Operation Can Be Claimed With D, E, F, G, H, J, Or K) 092303C 2008-2009 Escape, 1.6 Hrs. Escape Hybrid: Replace Both Front Seat Cushion Covers Includes Time To Reset The Occupant Classification Sensor (OCS) (This Labor Operation Can Be Claimed With D, E, F, G, H, J, Or K) 092303D 2008-2009 Escape, 0.7 Hr. Escape Hybrid: Replace One Front Seat Back Cover (This Labor Operation Can Be Claimed With A, B, C, F, G, H, J, Or K) 092303E 2008-2009 Escape, 1.0 Hr. Escape Hybrid: Replace Both Front Seat Back Covers (This Labor Operation Can Be Claimed With A, B, C, F, G, H, J, Or K) 092303F 2008-2009 Escape, 0.2 Hr. Escape Hybrid: Replace One Rear Seat Cushion Cover (This Labor Operation Can Be Claimed With D, E, H, J, Or K) 092303G 2008-2009 Escape, 0.4 Hr. Escape Hybrid: Replace Both Rear Seat Cushion Covers (This Labor Operation Can Be Claimed With D, E, H, J, Or K) 092303H 2008-2009 Escape, 0.6 Hr. Escape Hybrid: Replace The Right Rear Seat Back Cover (This Labor Operation Can Be Claimed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 09-23-3 > Nov > 09 > Interior - White Stains On Cloth Seat Covers > Page 7206 With A, B, C, E, F, G) 092303J 2008-2009 Escape, 1.0 Hr. Escape Hybrid: Replace The Left Rear Seat Back Covers (This Labor Operation Can Be Claimed With A, B, C, D, E, F, And G) 092303K 2008-2009 Escape, 1.2 Hrs. Escape Hybrid: Replace Both Rear Seat Back Covers (This Labor Operation Can Be Claimed With A, B, C, D, F, And G) DEALER CODING CONDITION BASIC PART NO. CODE 7862901 D4 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-23-3 > Nov > 09 > Interior - White Stains On Cloth Seat Covers Seat Cover: All Technical Service Bulletins Interior - White Stains On Cloth Seat Covers TSB 09-23-3 11/30/09 CLOTH SEAT STAINS WITH WHITE RING OUTLINE - BUILT ON OR BEFORE 5/14/2009 (EXCLUDES XLS) FORD: 2008-2009 Escape Hybrid, Escape ISSUE Some 2008-2009 Escape and Escape Hybrid vehicles (excludes Mariner) equipped with Cloth seats (excludes XLS) and built on or before 5/14/2009, may exhibit stains with a white ring outline around them. An updated seat cover is now available to reduce this specific type of staining. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Inspect the seat cover stain for a white ring outline. (Figure 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-23-3 > Nov > 09 > Interior - White Stains On Cloth Seat Covers > Page 7212 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-23-3 > Nov > 09 > Interior - White Stains On Cloth Seat Covers > Page 7213 2. If the white ring stain is present, then replace the seat cover with latest level part. (Figures 2-3) Refer to Workshop Manual (WSM), Section 501-10 Seating Disassembly and Assembly. NOTE ONLY APPLIES TO STAINS WITH WHITE RING OUTLINE. REFER TO WARRANTY AND POLICY MANUAL FOR ANY OTHER TYPE OF SEAT COVER STAINS. 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-23-3 > Nov > 09 > Interior - White Stains On Cloth Seat Covers > Page 7214 092303A 2008-2009 Escape, 0.9 Hr. Escape Hybrid: Replace The Left Front Seat Cushion Cover (This Labor Operation Can Be Claimed With D, E, F, G, H, J, Or K) 092303 2008-2009 Escape, 1.1 Hrs. Escape Hybrid: Replace The Right Front Seat Cushion Cover Includes Time To Reset The Occupant Classification Sensor (OCS) (This Labor Operation Can Be Claimed With D, E, F, G, H, J, Or K) 092303C 2008-2009 Escape, 1.6 Hrs. Escape Hybrid: Replace Both Front Seat Cushion Covers Includes Time To Reset The Occupant Classification Sensor (OCS) (This Labor Operation Can Be Claimed With D, E, F, G, H, J, Or K) 092303D 2008-2009 Escape, 0.7 Hr. Escape Hybrid: Replace One Front Seat Back Cover (This Labor Operation Can Be Claimed With A, B, C, F, G, H, J, Or K) 092303E 2008-2009 Escape, 1.0 Hr. Escape Hybrid: Replace Both Front Seat Back Covers (This Labor Operation Can Be Claimed With A, B, C, F, G, H, J, Or K) 092303F 2008-2009 Escape, 0.2 Hr. Escape Hybrid: Replace One Rear Seat Cushion Cover (This Labor Operation Can Be Claimed With D, E, H, J, Or K) 092303G 2008-2009 Escape, 0.4 Hr. Escape Hybrid: Replace Both Rear Seat Cushion Covers (This Labor Operation Can Be Claimed With D, E, H, J, Or K) 092303H 2008-2009 Escape, 0.6 Hr. Escape Hybrid: Replace The Right Rear Seat Back Cover (This Labor Operation Can Be Claimed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-23-3 > Nov > 09 > Interior - White Stains On Cloth Seat Covers > Page 7215 With A, B, C, E, F, G) 092303J 2008-2009 Escape, 1.0 Hr. Escape Hybrid: Replace The Left Rear Seat Back Covers (This Labor Operation Can Be Claimed With A, B, C, D, E, F, And G) 092303K 2008-2009 Escape, 1.2 Hrs. Escape Hybrid: Replace Both Rear Seat Back Covers (This Labor Operation Can Be Claimed With A, B, C, D, F, And G) DEALER CODING CONDITION BASIC PART NO. CODE 7862901 D4 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 Engine Control Module: All Technical Service Bulletins Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 TSB 10-18-3 09/27/10 HYBRID - MIL ON DTCS PO13A, P0030, P0130 AND/OR P0400 FORD: 2009-2010 Escape MERCURY: 2009-2010 Mariner This article supersedes TSB 09-20-6 to update the vehicle model years, Service Issue, Service Procedure and Service Labor Time Standards. ISSUE Some 2009 Escape Hybrid and Mariner Hybrid vehicles may exhibit a malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P013A and/or P0400. Vehicles built on or before 6/24/2009 with DTC P013A may be caused by an exhaust leak at the manifold catalyst flange. Some 2010 Escape Hybrid and Mariner Hybrid vehicles may exhibit any of the following DTCs; P013A , P0030, and P0130 and/or P0400. An improved calibration is available for these vehicles. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Vehicles with a DTC P013A built on or before 6/24/2009 follow Procedure A and B. Vehicles built on or after 6/25/2009 perform Procedure B. Procedure A 1. Restrict exhaust flow at the tailpipe and inspect for carbon soot/moisture witness marks indicating a leak at the manifold catalyst flange. Misting a soapy water spray solution on the flange while the exhaust is restricted will increase the ability to identify and confirm leaks. 2. Is a leak present? a. No - Skip to Procedure B. b. Yes - Proceed to Step 3. 3. Disconnect the intermediate exhaust pipe from the manifold catalyst. Refer to Workshop Manual (WSM), Section 309-00. 4. Inspect the flange for evidence of weld or other material that is raised on the sealing surface and may prevent complete sealing at the joint. If this condition is found, replace the manifold catalyst assembly and both heated oxygen sensors (H025). Refer to WSM 309-00. 5. Proceed to Procedure B. Procedure B Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 68.07 and higher or 69.01 and higher. This new calibration is not included in the VCM 2010.9 DVD. Calibration files may also be obtained at the website. Parts Block Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 7221 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0442/P0456/P1450 TSB 10-1-3 02/01/10 HYBRID ONLY - DTCS P0442, P0456 OR P1450 - BUILT ON OR BEFORE 4/6/2009 FORD: 2010 Fusion 2009 Escape MERCURY: 2010 Milan 2009 Mariner This article supersedes TSB 09-9-9 to add a production fix date. ISSUE Some 2009 Escape Hybrid, Mariner Hybrid, 2010 Fusion Hybrid and Milan Hybrid vehicles built on or before 4/6/2009 may exhibit a malfunction indicator light (MIL) accompanied by diagnostic trouble code (DTC) P0442, P0456 or P1450. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Follow the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostic procedures for any DTC code that may be present to ensure the Evaporative Emissions (EVAP) system is functioning properly. 2. When performing EVAP diagnostics on Escape Hybrid and Mariner Hybrid vehicles, the ambient temperature must be greater than 32 °F (0 °C) and the heating ventilation air conditioning (HVAC) system should be set to Defrost. This will provide continuous gasoline engine operation. 3. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 60.11 and higher or 61.01 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 100103A 2010 Fusion Hybrid/Milan 0.3 Hr. Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) 100103A 2009 Escape 0.3 Hr. Hybrid/Mariner Hybrid: Check For DTCs And Reprogram The PCM (For Additional Repairs On EVAP System Use SLTS Operations If Available Claim Additional Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 7226 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 10-18-3 > Sep > 10 > Engine Controls/Exhaust - MIL ON/DTCs P013A/P0130/P0400 > Page 7232 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 101803A 2009-2010 Escape Hybrid, 0.3 Hr. Mariner Hybrid: Check DTCs, Reprogram The PCM (Do Not Use With Any Other Labor Operations) 101803B 2009-2010 Escape Hybrid, 1.7 Hrs. Mariner Hybrid: Check DTCs, Replace The Manifold Catalyst Assembly And Both HO2S Sensors, Then Reprogram The PCM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5G232 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 10-1-3 > Feb > 10 > Engine Controls - MIL ON/DTC's P0442/P0456/P1450 > Page 7237 BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats Seat Cover: Service and Repair Front Seats Seat - Exploded View, Front Seat - Exploded View, Front Seat Backrest - Front NOTE: Driver seat shown, passenger seat similar. Seat Cushion - Driver NOTE: Power seat track shown, manual seat track similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7240 Seat Cushion - Front, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7241 1. For additional information, refer to the procedures. Seat Backrest Cover - Front Seat Backrest Cover - Front Removal and Installation Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7242 WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag material has been exposed, install a new seat side air bag module. Never try to repair the seat side air bag module. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. NOTE: If a side air bag deployment took place, a new seat back pad, trim cover and side air bag module and nuts must be installed. The seat back frame should be replaced if necessary. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition switch is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: Driver seat shown, passenger seat similar. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures portion of Air Bag Systems. 2. Press the buttons and remove the head restraint. 3. NOTE: The head restraint guides are not interchangeable. Pull and remove the 2 head restraint guides. 4. If equipped, remove the lumbar adjust knob. 5. Release the J-clip at the bottom of the front seat backrest cover. 6. If equipped, disconnect the backrest heater mat electrical connector and route through the elastic loop in the backrest trim cover. 7. NOTICE: Use care when separating the seat backrest trim cover from the hook-and-loop strip or the hook-and-loop strip can be torn from the seat backrest foam. Partially invert the backrest cover up to the side air bag. - Separate the hook-and-loop strips. 8. Release the side air bag module deployment chute J-clip. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7243 9. WARNING: Check the seat side air bag deployment chute for damage. The deployment chute must not be repaired. If there is any damage to the deployment chute, a new seat back trim cover and deployment chute must be installed as a unit. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. Pull the side air bag module deployment chute and J-clips through the opening in the backrest foam pad. Note positioning of the deployment chute for correct installation. 10. Invert and remove the backrest trim cover. 11. WARNING: If the seat side air bag module deployment chute is not correctly positioned and closed, the seat side air bag module may not deploy correctly. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increases the risk of serious personal injury or death in a crash. To install, reverse the removal procedure. 12. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures portion of Air Bag Systems. Seat Cushion Cover - Front Seat Cushion Cover - Front Removal and Installation NOTICE: Do not install a new heater mat on a front passenger seat cushion, it is not serviceable separately. If a new cushion heater mat is needed on the front passenger seat, an Occupant Classification Sensor (OCS) system service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. Refer to Air Bag Systems for the OCS removal and installation procedure. All seats 1. Remove the front seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. 2. Remove the front seat cushion. For additional information, refer to Seat Cushion - Front See: Seat Cushion/Service and Repair/Removal and Replacement/Front Seat Cushion. 3. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strips or the hook-and-loop strips may be torn from the seat cushion foam pad. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7244 Release the J-clips and remove the cushion trim cover. - Separate the hook-and-loop strips. - If equipped, note heater mat wire harness routing for correct installation. 4. NOTICE: Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion trim cover to the seat cushion pad. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect operation of the Occupant Classification Sensor (OCS) system and may cause system failure. To install, reverse the removal procedure. 5. Install the front seat. If a passenger seat has been serviced, do not prove out the Supplemental Restraint System (SRS) at this time. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. Passenger seat 6. WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTICE: To prevent system failure, the following precautions must be taken before carrying out the Occupant Classification Sensor (OCS) system reset: Make sure the voltage to the Occupant Classification System Module (OCSM) is above 8 volts and less than 18 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. Carry out the Occupant Classification Sensor (OCS) system reset. 7. If the first system reset attempt was unsuccessful, carry out a thorough visual inspection of the following and repair any concerns found. - OCS system connector and wiring for damage - Pressure sensor hose for kinks and/or damage - Seat-related wiring harness and body wiring harness terminals and connectors for damage 8. NOTE: The ignition switch must be cycled after the OCS system reset. Carry out a second OCS system reset. If the second attempt is unsuccessful, install a new OCS system service kit. For additional information, refer to Occupant Classification System Service Kit in Air Bag Systems. 9. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is detected, the air bag warning indicator will: - 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 warning indicator is inoperative and a Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7245 SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7246 Seat Cover: Service and Repair Rear Seat Backrest Cover Seat Backrest Cover - Rear NOTE: For component identification and locations, refer to Seat - Exploded View, Rear See: Service and Repair/Rear Seat - Exploded View. 1. Remove the rear seat backrest. For additional information, refer to Seat Backrest - Rear See: Seat Back/Service and Repair/Removal and Replacement/Rear Seat Backrest. 2. Remove the head restraint(s). 3. Remove the 2 screws and latch cover. 4. Remove the 2 seat latch release handle screws. 5. Remove the seat latch release handle. 1. Detach the latch rod from the seat latch release handle. - To aid installation, lock the latch using a flat-blade screwdriver before connecting the latch rod. 2. Remove the seat latch release handle. 6. Release the backrest cover J-clip. 7. Unzip the backrest trim cover zipper. 8. NOTE: The inboard and outboard head restraint guides are not interchangeable. Squeeze together the tip of each head restraint guide and remove from the backrest frame. - Note the alignment tab position for correct installation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7247 9. If 60 percent backrest, remove the 2 screws and safety belt shield. 10. NOTICE: Use care when separating the seat backrest trim cover from the hook-and-loop strip or the hook-and-loop strip can be torn from the seat backrest foam pad. Separate the hook-and-loop strips and remove the seat backrest trim cover. 11. NOTE: Make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement Seat Cushion: Removal and Replacement Front Seat Cushion Seat Cushion - Front Removal and Installation NOTICE: To prevent system failure, it is necessary to carry out the Occupant Classification Sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. NOTE: For component identification and locations, refer to Seat - Exploded View, Front See: Service and Repair/Front Seats/Seat - Exploded View, Front. All seats 1. Remove the front seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. Passenger seat 2. NOTE: To identify between a production Occupant Classification Sensor (OCS) system and a service OCS system (OCS service kit), inspect the electrical connector. A production OCS system allows the disconnect of the Occupant Classification System Module (OCSM) electrical connector. A service OCS system (OCS service kit) has the electrical connector glued to the OCSM. It cannot and should not be disconnected or altered. NOTE: If removing a production OCS system or an OCS system service kit, refer to the appropriate procedure in Air Bag Systems. Disconnect the OCS wiring harness. For an original equipment OCS system, disconnect the OCSM and pressure sensor electrical connectors. - For an OCS system service kit, disconnect the seat wire harness OCS electrical connector from the service part OCS electrical connector. Heated seat 3. Disconnect the backrest heater mat electrical connector. - Access the electrical connector by slightly pulling the wiring harness out from the backrest cover. 4. Disconnect and detach the cushion heater mat electrical connector. 5. Release the locking tab and remove the heated seat relay from the bracket on the cushion frame. All seats 6. Detach all wiring harness pin-type retainers from the seat cushion frame. - Note wiring harness routing for correct installation. 7. Remove the 4 seat track-to-cushion frame bolts. - To install, tighten to 25 Nm (18 lb-ft). 8. Remove the seat cushion. 9. To install, reverse the removal procedure. 10. Install the front seat. If a passenger seat has been serviced, do not prove out the Supplemental Restraint System (SRS) at this time. For Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7252 additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. Passenger seat 11. WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTICE: To prevent system failure, the following precautions must be taken before carrying out the Occupant Classification Sensor (OCS) system reset: Make sure the voltage to the Occupant Classification System Module (OCSM) is above 8 volts and less than 18 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. Carry out the OCS system reset. 12. If the first system reset attempt was unsuccessful, carry out a thorough visual inspection of the following and repair any concerns found. - OCS system connector and wiring for damage - Pressure sensor hose for kinks and/or damage - Seat-related wiring harness and body wiring harness terminals and connectors for damage 13. NOTE: The ignition switch must be cycled after the OCS system reset. Carry out a second OCS system reset. If the second attempt is unsuccessful, install a new OCS system service kit. For additional information, refer to Occupant Classification System Service Kit in Air Bag Systems. 14. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is detected, the air bag warning indicator will: - 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 warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and OCSM using a scan tool. Rear Seat Cushion Cover Seat Cushion Cover - Rear Removal and Installation 1. Remove the rear seat cushion. - Position the seat cushion forward. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7253 - Release the locking tab and slide the rear seat cushion outward. 2. Unzip the cushion cover zipper. 3. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strips or the hook-and-loop strips may be torn from the seat cushion foam pad. Invert and remove the cushion cover. 4. NOTE: Make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7254 Seat Cushion: Overhaul Seat Cushion - Driver Seat Cushion - Driver NOTE: Power seat track shown, manual similar. Disassembly 1. Remove the seat backrest. For additional information, refer to Seat Backrest - Front See: Seat Back/Service and Repair/Removal and Replacement/Front Seats/Seat Backrest - Front. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7255 2. Remove the safety belt buckle pretensioner. - Disconnect and detach the safety belt buckle pretensioner and buckle switch electrical connectors from the seat track. - Detach the wiring harness pin-type retainer. - Route the wiring harness from between the seat track and cushion frame. 3. Disconnect the electrical connector(s). - Disconnect the seat position sensor electrical connector and detach the wiring harness. - If equipped, disconnect the power seat track electrical connector and detach the wiring harness. - Detach the seat harness electrical connector from the seat track. 4. Remove the 4 bolts and seat track. - To install, tighten to 25 Nm (18 lb-ft). 5. If equipped, disconnect the cushion heater mat electrical connector. 6. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strips or the hook-and-loop strips may be torn from the seat cushion foam pad. Release the all the retainers and remove the cushion cover. 7. Remove the cushion foam pad. - If equipped, note heater mat wire harness routing for correct installation. 8. If equipped, release the locking tab and remove the heated seat relay from the bracket on the cushion frame. - Disconnect the relay electrical connector. 9. To assemble, reverse the disassembly procedure. Seat Cushion - Front, Passenger Side Seat Cushion - Front, Passenger Side NOTE: Seat equipped with a production Occupant Classification Sensor (OCS) system shown. For OCS system service components, refer to Occupant Classification Sensor - Service Kit procedure in Air Bag Systems. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7256 Disassembly NOTICE: To prevent system failure, it is necessary to carry out the Occupant Classification Sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. NOTICE: Do not install a new heater mat on a front passenger seat cushion, it is not serviceable separately. If a new cushion heater mat is needed on the front passenger seat, an Occupant Classification Sensor (OCS) system service kit equipped with a heater mat must be installed. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7257 Failure to follow this instruction may result in incorrect operation of the OCS system. Refer to Air Bag Systems for the OCS removal and installation procedure. NOTE: OCS system components, seat cushion foam pad, bladder with pressure sensor and Occupant Classification System Module (OCSM), are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and OCSM) must be installed as an assembly. All seats 1. Remove the seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. 2. Remove the seat backrest. For additional information, refer to Seat Backrest - Front See: Seat Back/Service and Repair/Removal and Replacement/Front Seats/Seat Backrest - Front. 3. Remove the safety belt buckle pretensioner. - Disconnect and detach the safety belt buckle pretensioner and buckle switch electrical connectors from the seat track. - Detach the wiring harness pin-type retainer. - Route the wiring harness from between the seat track and cushion frame. 4. NOTE: Note wiring harness routing for installation. Detach the seat harness electrical connector and wiring harness from the seat track. 5. Remove the 4 seat track-to-cushion frame bolts. 6. If equipped, disconnect the heated seat system components. - Disconnect and detach the cushion heater mat electrical connector. - Release the locking tab and remove the heated seat relay from the bracket on the cushion frame. - Disconnect the heated seat relay electrical connector. Seat with original equipment Occupant Classification Sensor (OCS) system 7. WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTE: To identify between a production OCS system and a service OCS system (OCS service kit), inspect the electrical connector. A production OCS system allows the disconnect of the OCSM electrical connector. A service OCS system (OCS service kit) has the electrical connector glued to the OCSM. It cannot and should not be disconnected or altered. Disconnect the electrical connectors and wiring clips. 1. Disconnect the OCSM electrical connector. 2. Disconnect the pressure sensor electrical connector. - Detach the wiring harness retainers and wiring harness from the cushion frame. 8. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strips or the hook-and-loop strips may be torn from the seat cushion foam pad. Release all cushion cover retainers and remove the cushion cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7258 9. Remove the cushion foam pad. 10. Bend the retaining tab away from the pressure sensor, then slide the pressure off the bracket. 11. NOTICE: Care must be taken to prevent damage to the seat cushion frame when removing the rivets. Remove the 2 rivets and the OCSM. 12. Remove the 2 pin-type retainers from the OCS bladder and seat cushion frame. 13. Feed the OCS hose and pressure sensor through the seat cushion frame opening and remove as an assembly with the bladder. Seat with OCS system service kit 14. Disconnect the electrical connector and wiring clips. 1. Disconnect the seat wire harness OCSM electrical connector from the service part OCS electrical connector. 2. Release the 2 wiring clips on the wiring harness from the cushion frame. 15. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strips or the hook-and-loop strips may be torn from the seat cushion foam pad. Release all cushion cover retainers and remove the cushion cover. 16. Bend the retaining tab away from the pressure sensor, then slide the pressure off the bracket. 17. NOTICE: Care must be taken to prevent damage to the seat cushion frame when removing the rivets. Remove the 2 rivets and detach the OCSM from the seat cushion frame. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7259 18. Remove the OCS. - Pull all the OCS components (hose, pressure sensor, wire harness, OCSM and connectors) through the seat cushion frame opening. Assembly All seats 1. Bend the retaining tab back on the pressure sensor component bracket. Seat with original equipment OCS system 2. NOTICE: Failure to route the seat Occupant Classification Sensor (OCS) components through the correct seat cushion support opening can cause component failure. NOTICE: While positioning the seat cushion frame and Occupant Classification Sensor (OCS), be careful not to damage any of the components. Failure to do so can result in component failure. Feed the OCS system components (pressure sensor and hose) through the opening in the seat cushion frame. 3. Align the OCS bladder to the seat cushion frame. 4. Install the 2 pin-type retainers to the OCS bladder and seat cushion frame. 5. NOTE: Make sure the pressure sensor hose is not kinked during installation. Install the pressure sensor onto the seat cushion frame bracket, making sure the retaining tab is completely engaged. - When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab. 6. Slide the OCSM into the seat cushion frame bracket and install the rivets. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7260 - The OCSM must be correctly positioned and securely fastened in place. Failure to do so can set a DTC in the Restraints Control Module (RCM). 7. Position the foam pad to the seat cushion frame. 8. NOTICE: Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion trim cover to the seat cushion pad. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect operation of the Occupant Classification Sensor (OCS) system and may cause system failure. Install the cushion cover and attach the retainers to the cushion frame. 9. NOTICE: While positioning the seat cushion frame and Occupant Classification Sensor (OCS), be careful not to damage any of the components. Failure to do so can result in component failure. Position the seat cushion assembly to the seat track and install the 4 seat track-to-cushion frame bolts. - Tighten to 25 Nm (18 lb-ft). 10. Install the wiring harness. 1. Connect the OCSM electrical connector. 2. Connect the pressure sensor electrical connector. - Attach the wiring harness to the cushion frame. Seat with OCS system service kit 11. NOTICE: Inspect the Occupant Classification Sensor (OCS) bladder, seat cushion frame and support assembly for any foreign objects, before installing the OCS to the seat cushion frame. If any foreign objects are found, remove them. Failure to follow these instructions may result in incorrect operation of the OCS system and may cause system failure. NOTICE: Failure to route the seat Occupant Classification Sensor (OCS) components through the correct seat cushion support opening can cause component failure. NOTICE: While positioning the seat cushion frame and Occupant Classification Sensor (OCS), be careful not to damage any of the components. Failure to do so can result in component failure. Route the OCS system service kit components (hose, pressure sensor, OCSM, wire harness and connectors) through the opening in the seat cushion frame. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7261 12. NOTE: When installing a service part OCS, the seat wire harness pressure sensor electrical connector is not used. NOTE: Make sure the pressure sensor hose is not kinked during installation. Install the OCS system components to the seat cushion frame. 1. Install the pressure sensor onto the seat cushion frame bracket, making sure the retaining tab is completely engaged. - When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab. 2. Slide the OCSM into the seat cushion frame bracket. - The OCSM must be correctly positioned and securely fastened in place. Failure to do so can set a DTC in the RCM. 3. Install the rivets. 13. Install the cushion cover and attach the retainers to the seat cushion frame. 14. NOTICE: While positioning the seat cushion frame and Occupant Classification Sensor (OCS), be careful not to damage any of the components. Failure to do so can result in component failure. Position the seat cushion assembly to the seat track and install the 4 seat track-to-cushion frame bolts. - Tighten to 25 Nm (18 lb-ft). 15. NOTE: Do not tie strap any wiring to the OCS bladder and pressure sensor hose. - Connect the seat wire harness OCS system electrical connector to the service part OCS system electrical connector. - Install the 2 wiring clips on the wiring harness to the cushion frame. - Tie strap the unused seat wire harness pressure sensor electrical connector safely aside. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7262 - Tie strap all loose wire harnesses and electrical connectors safety aside. All seats 16. If equipped, connect the heated seat components. - Install the heated seat relay to the bracket on the cushion frame. - Connect the heated seat relay electrical connector. - Connect the cushion heater mat electrical connector and attach to the cushion frame. 17. Attach the seat electrical connector and wiring harness to the seat track. 18. Connect the safety belt buckle pretensioner and buckle switch electrical connectors. - Route the wiring harness between the seat track and cushion frame. - Attach the wiring harness pin-type retainer. 19. Install the seat backrest. For additional information, refer to Seat Backrest - Front See: Seat Back/Service and Repair/Removal and Replacement/Front Seats/Seat Backrest - Front. 20. Install the seat. Do not prove out the Supplemental Restraint System (SRS) at this time. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. 21. WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTICE: To prevent system failure, the following precautions must be taken before carrying out the Occupant Classification Sensor (OCS) system reset: Make sure the voltage to the Occupant Classification System Module (OCSM) is above 8 volts and less than 18 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. Carry out the OCS system reset. 22. If the first system reset attempt was unsuccessful, carry out a thorough visual inspection of the following and repair any concerns found. - OCS system connector and wiring for damage - Pressure sensor hose for kinks and/or damage - Seat-related wiring harness and body wiring harness terminals and connectors for damage 23. NOTE: The ignition switch must be cycled after the OCS system reset. Carry out a second OCS system reset. If the second attempt is unsuccessful, install a new OCS system service kit. For additional information, refer to Occupant Classification System Service Kit in Air Bag Systems. 24. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is detected, the air bag warning indicator will: - fail to light. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7263 - 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 RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and OCSM using a scan tool. Rear Seat Cushion Seat Cushion - Rear NOTE: RH (40 percent) shown, LH (60 percent) similar. Disassembly and Assembly 1. Remove the rear seat cushion. - Position the seat cushion forward. - Release the locking tab and slide the rear seat cushion outward. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7264 2. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strips or the hook-and-loop strips may be torn from the seat cushion foam pad. Unzip the cushion cover zipper. 3. Invert and remove the cushion cover. 4. Remove the 2 bolts and cushion pivot upper link. - To install, tighten to 40 Nm (30 lb-ft). 5. Remove the 2 cushion hinge floor bracket bolts and cushion support-to-floor bracket. - To install, tighten to 40 Nm (30 lb-ft). 6. To assemble, reverse the disassembly procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions Seat Heater: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7269 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7270 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7271 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7272 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7273 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7274 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7275 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7276 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7277 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7278 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7279 Seat Heater: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7280 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7281 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7282 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7283 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7284 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7285 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7286 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7287 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7288 Seat Heater: Connector Views Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7289 Seat Heater: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 119-1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7290 119-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 7291 Seat Heater: Service and Repair Seat - Exploded View, Front Seat Backrest - Front NOTE: Driver seat shown, passenger seat similar. Seat Cushion - Driver NOTE: Power seat track shown, manual seat track similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 7292 Seat Cushion - Front, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 7293 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair Seat Heater Control Module: Service and Repair Seat - Exploded View, Front Seat Backrest - Front NOTE: Driver seat shown, passenger seat similar. Seat Cushion - Driver NOTE: Power seat track shown, manual seat track similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Page 7297 Seat Cushion - Front, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Page 7298 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Locations > Heated Seats Relay Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Locations > Heated Seats Relay > Page 7303 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Diagrams > Heated Seat Relay, Driver Seat Heater Relay: Diagrams Heated Seat Relay, Driver Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Diagrams > Heated Seat Relay, Driver > Page 7306 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Diagrams > Heated Seat Relay, Driver > Page 7307 Seat Heater Relay: Diagrams Heated Seat Relay, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Diagrams > Heated Seat Relay, Driver > Page 7308 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front Seat Heater Switch: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Seat Backrest - Front NOTE: Driver seat shown, passenger seat similar. Seat Cushion - Driver NOTE: Power seat track shown, manual seat track similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7313 Seat Cushion - Front, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7314 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7315 Seat Heater Switch: Service and Repair Seat Control Switch Seat Control Switch Removal and Installation NOTE: For component identification and locations, refer to Seat - Exploded View, Front See: Service and Repair/Front Seats/Seat - Exploded View, Front. 1. Remove the recliner handle cover. 2. Remove the seat control switch knob. 3. Remove the outboard side shield. - Remove the 3 screws and detach the side shield. - Disconnect the seat control switch electrical connector. 4. Remove the knob and seat control switch. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track Seat Track: Service and Repair Seat Track Seat Track Removal and Installation NOTE: For component identification and locations, refer to Seat - Exploded View, Front See: Service and Repair/Front Seats/Seat - Exploded View, Front. 1. Remove the front seat backrest. For additional information, refer to Seat Backrest - Front See: Seat Back/Service and Repair/Removal and Replacement/Front Seats/Seat Backrest - Front. 2. Remove the safety belt buckle pretensioner. - Disconnect and detach the safety belt buckle pretensioner and buckle switch electrical connectors from the seat track. - Detach the wiring harness pin-type retainer. - Route the wiring harness from between the seat track and cushion frame. 3. Disconnect the electrical connectors, detach the wiring harness from the seat track. - If driver seat, disconnect the seat position sensor electrical connector. - If equipped, disconnect the power seat motor electrical connector. - Detach the seat harness electrical connector from the seat track. Note wiring harness routing for correct installation. 4. Remove the 4 seat track-to-cushion frame bolts. - To install, tighten to 25 Nm (18 lb-ft). 5. To install, reverse the removal procedure. - Transfer components as necessary. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track > Page 7320 Seat Track: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Seat Backrest - Front NOTE: Driver seat shown, passenger seat similar. Seat Cushion - Driver NOTE: Power seat track shown, manual seat track similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track > Page 7321 Seat Cushion - Front, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track > Page 7322 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Console Lamp Switch > Component Information > Service and Repair Console Lamp Switch: Service and Repair Ambient Lighting Switch Removal and Installation 1. Remove the floor console finish panel. - Disconnect the electrical connector. 2. Squeeze the retaining tabs and remove the ambient lighting switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 7331 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 7334 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 7335 Power Door Lock Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 7336 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 7337 Power Door Lock Switch: Service and Repair Door Lock Control Switch NOTE: LH side shown, RH side similar. Removal and Installation 1. Remove the front interior door handle. For additional information, refer to Interior Door Handle Front See: Doors, Hood and Trunk/Doors/Front Door/Front Door Handle/Front Door Interior Handle/Service and Repair/Interior Door Handle Front. 2. Release the tabs and remove the door lock control switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7341 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7342 Power Mirror Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7343 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7344 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7345 Power Mirror Switch: Service and Repair Exterior Mirror Control Switch Removal and Installation 1. Remove the LH sail panel. - Disconnect the electrical connector. 2. Remove the exterior mirror control switch. - Press the 2 retaining tabs. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 7349 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 7350 Power Seat Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 7351 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 7352 Power Seat Switch: Service and Repair Seat - Exploded View, Front Seat Backrest - Front NOTE: Driver seat shown, passenger seat similar. Seat Cushion - Driver NOTE: Power seat track shown, manual seat track similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 7353 Seat Cushion - Front, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 7354 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Service and Repair > Liftgate Release Switch Power Trunk / Liftgate Lock Switch: Service and Repair Liftgate Release Switch Liftgate Release Switch Removal and Installation 1. Remove the liftgate trim panel. 2. Remove the 4 liftgate trim bezel nuts and remove the bezel from the liftgate. - To install, tighten to 8 Nm (71 lb-in). - Disconnect the electrical connector. - Using the appropriate tool, press the tabs and remove the liftgate release switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Service and Repair > Liftgate Release Switch > Page 7360 Power Trunk / Liftgate Lock Switch: Service and Repair Liftgate Release Switch - Liftgate Window Liftgate Release Switch - Liftgate Window Removal and Installation 1. Remove the liftgate trim panel. 2. Remove the 4 liftgate trim bezel nuts and remove the bezel from the liftgate. - To install, tighten to 8 Nm (71 lb-in). - Disconnect the liftgate window release switch electrical connector. - Using the appropriate tool, press the tabs and remove the liftgate window release switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front Seat Heater Switch: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Seat Backrest - Front NOTE: Driver seat shown, passenger seat similar. Seat Cushion - Driver NOTE: Power seat track shown, manual seat track similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7365 Seat Cushion - Front, Passenger Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7366 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7367 Seat Heater Switch: Service and Repair Seat Control Switch Seat Control Switch Removal and Installation NOTE: For component identification and locations, refer to Seat - Exploded View, Front See: Seats/Service and Repair/Front Seats/Seat - Exploded View, Front. 1. Remove the recliner handle cover. 2. Remove the seat control switch knob. 3. Remove the outboard side shield. - Remove the 3 screws and detach the side shield. - Disconnect the seat control switch electrical connector. 4. Remove the knob and seat control switch. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Roof Opening Panel Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Roof Opening Panel Switch > Page 7372 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 7373 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 7374 Sunroof / Moonroof Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 7375 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations > Page 7379 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Switch: > 10-5-1 > Mar > 10 > Body - Uncommanded Liftgate Opening Trunk / Liftgate Switch: Customer Interest Body - Uncommanded Liftgate Opening TSB 10-5-1 03/29/10 LIFTGATE OPENING UN-COMMANDED OR NOT OPENING WHEN COMMANDED WHEN PARKED - INTERMITTENT FORD: 2008-2009 Escape MERCURY: 2008-2009 Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles built on or before 8/31/2008 may exhibit the liftgate opening un-commanded, or not opening when commanded while vehicle is parked. This may be due to water intrusion into the switch connector causing corrosion at the liftgate rear switch. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Refer to Workshop Manual (WSM), Section 501-14 for additional diagnostics. 1. Remove the liftgate trim panel. Refer to WSM, Section 501-05. 2. Remove the four (4) liftgate trim bezel nuts and remove the bezel from the liftgate. 3. Closely inspect the liftgate release switch and harness connector pins for signs of water intrusion and/or corrosion. Is any evidence of water intrusion or corrosion present? (Figure 1) a. No - Do not continue with this procedure. Refer to WSM, Section 501-14 for additional diagnostics. b. Yes - Replace the liftgate release switch per WSM, Section 501-14, and install new Pigtail Wiring Kit per Wiring Diagram, Section 5-1. Parts Block 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Switch: > 10-5-1 > Mar > 10 > Body - Uncommanded Liftgate Opening > Page 7388 100S01A 2008-2009 Escape, 0.6 Hr. Mariner: Replace The Liftgate Release Switch And The Wiring Pigtail (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 13412 12 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Switch: > 10-5-1 > Mar > 10 > Body - Uncommanded Liftgate Opening Trunk / Liftgate Switch: All Technical Service Bulletins Body - Uncommanded Liftgate Opening TSB 10-5-1 03/29/10 LIFTGATE OPENING UN-COMMANDED OR NOT OPENING WHEN COMMANDED WHEN PARKED - INTERMITTENT FORD: 2008-2009 Escape MERCURY: 2008-2009 Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles built on or before 8/31/2008 may exhibit the liftgate opening un-commanded, or not opening when commanded while vehicle is parked. This may be due to water intrusion into the switch connector causing corrosion at the liftgate rear switch. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Refer to Workshop Manual (WSM), Section 501-14 for additional diagnostics. 1. Remove the liftgate trim panel. Refer to WSM, Section 501-05. 2. Remove the four (4) liftgate trim bezel nuts and remove the bezel from the liftgate. 3. Closely inspect the liftgate release switch and harness connector pins for signs of water intrusion and/or corrosion. Is any evidence of water intrusion or corrosion present? (Figure 1) a. No - Do not continue with this procedure. Refer to WSM, Section 501-14 for additional diagnostics. b. Yes - Replace the liftgate release switch per WSM, Section 501-14, and install new Pigtail Wiring Kit per Wiring Diagram, Section 5-1. Parts Block 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Switch: > 10-5-1 > Mar > 10 > Body - Uncommanded Liftgate Opening > Page 7394 100S01A 2008-2009 Escape, 0.6 Hr. Mariner: Replace The Liftgate Release Switch And The Wiring Pigtail (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 13412 12 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > Page 7395 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Technical Service Bulletins > Page 7396 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Insulation Sound Proofing / Insulation: Description and Operation Insulation Insulation Insulation is used as a sound-deadener to reduce exterior road and powertrain noises from the interior of the vehicle. Mastic insulators are also used as insulation. For information on the location of the mastic insulators, refer to Sound Deadeners and Insulators. See: Sound Deadeners and Insulators Insulation is installed: - under the roof. - above and below the instrument panel. - at the cowl side panels. - over the front and rear floor pans. - inside the A-, B-, D-pillar sections. - behind the rear quarter trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Insulation > Page 7401 Sound Proofing / Insulation: Description and Operation Sound Deadeners and Insulators SOUND DEADENERS AND INSULATORS WARNING: Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and wear protective equipment as directed. Examples may include but are not limited to respirators and chemically resistant gloves. Failure to follow these instructions may result in serious personal injury. NOTICE: - Mastic is made of a combustible material and should be removed prior to carrying out welding procedures to the area. Heat zones from welding near the mastic can cause the mastic material to burn. - Corrosion protection must be restored to the area AFTER the mastic material is applied. Corrosion protection products may be wax based and loss of adhesion may occur. NOTE: - To restore the vehicle to design intent, missing or damaged sound deadeners and insulators should be installed with the correct service replacement component. - The following illustrations serve as a reference to indicate mastic patch (butyl pad) locations. Additional insulators and sound deadeners are used beyond those indicated in the illustration. Sound Deadeners and Insulators Floor Pan Sound Deadeners NOTE: To restore the vehicle to design intent, missing or damaged sound deadeners and insulators should be installed with the correct service replacement component. Sound deadeners in this illustration all use base part number 99P30A3. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Insulation > Page 7402 Floor Pan Sound Deadeners Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 2 wiper pivot arms nuts. - To install, tighten to 35 Nm (26 lb-ft). 2. Remove the LH and RH wiper pivot arms. 3. Remove the LH and RH cowl end cap pushpin retainers. 4. Remove the cowl end caps. 5. Release the cowl panel grille from the retaining clips and remove the cowl panel grille. 6. To install, reverse the removal procedure. - Adjust the wiper pivot arms. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched Front Door Window Glass Weatherstrip: Customer Interest Body - Front/Rear Door Window Noise/Glass Scratched TSB 11-2-15 02/28/11 WINDOW SQUEAK NOISE AND/OR VERTICAL WINDOW GLASS SCRATCH - BUILT ON OR BEFORE 8/13/2010 FORD: 2008-2011 Escape MERCURY: 2008-2011 Mariner This article supersedes TSB 10-25-5 to update the Part List. ISSUE Some 2008-2011 Escape and Mariner vehicles built on or before 8/13/2010 may exhibit a front and/or rear window glass squeak noise with or without side window vertical window glass scratch. This may be due to a tolerance stack up condition and/or incorrect door flange adjustment. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Fully lower the affected window glass. 2. Remove the exterior door glass weatherstrip. Refer to Workshop Manual (WSM), Section 501-11 (Exploded View). 3. Fully raise the window glass. 4. Measure the distance from the inside edge of the weatherstrip flange to the outside sur[ace of the window glass. Is the distance within specification range of 1/4" (6 mm) to 3/8" (10 mm)? a. Yes - Proceed to Step 5. b. No - Using a suitable tool, evenly adjust the flange into specification. Proceed to Step 5. 5. Inspect the side window glass for evidence of vertical scratches. Are scratches present? a. Yes - Replace the affected side window glass and exterior door glass weatherstrip. Refer to WSM, Section 501-11. b. No - Replace the affected exterior door glass weatherstrip. Refer to WSM, Section 501-11. 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 110215A 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 110215B 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 7417 With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215C 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215D 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors 110215E 2008-2011 Escape, 0.5 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 11021SF 2008-2011 Escape, 1.0 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215G 2008-2011 Escape, 0.8 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215H 2008-2011 Escape, 1.5 Hrs. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 7821453 41 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 7418 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass Weatherstrip: > 10-25-4 > Dec > 10 > Body - Front Door Window Exterior Weatherstrip Deformed Front Door Window Glass Weatherstrip: Customer Interest Body - Front Door Window Exterior Weatherstrip Deformed TSB 10-25-4 12/23/10 FRONT EXTERIOR DOOR GLASS WEATHERSTRIP DEFORMED OR LIFTING - BUILT ON OR BEFORE 517/2010 12/23/10 FORD: 008-2010 Escape MERCURY: 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 5/7/2010 may exhibit the front exterior door glass weatherstrip deformed and/or lifting up from the door flange. This may be due to a lack of retention between the door glass weatherstrip and flange. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove affected front exterior door glass weatherstrip. Reference Workshop Manual (WSM), Section 501-11 Glass, Frames, and Mechanisms Exploded View. 2. Apply a strip of 3M(TM) Safety-Walk(TM) Slip-Resistant General Purpose Tapes, or similar (obtained locally) to the outer flange surface at the center of the door. Cut grip tape to approximately 2.5" X .5" (64 mm X 13 mm). (Figure 1) 3. Install new revised exterior door glass weatherstrip. Reference WSM, Section 501-11 Glass, Frames, and Mechanisms - Exploded View. 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 102504A 2008-2010 Escape, 0.2 Hr. Mariner: Replace One Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass Weatherstrip: > 10-25-4 > Dec > 10 > Body - Front Door Window Exterior Weatherstrip Deformed > Page 7423 Exterior Door Glass Weather Strip Includes Time To Install Grip Tape (Do Not Use With Any Other Labor Operations) 102504B 2008-2010 Escape, 0.3 Hr. Mariner: Replace Both Exterior Door Glass Weather Strips Includes Time To Install Grip Tape (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7821453 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched Front Door Window Glass Weatherstrip: All Technical Service Bulletins Body - Front/Rear Door Window Noise/Glass Scratched TSB 11-2-15 02/28/11 WINDOW SQUEAK NOISE AND/OR VERTICAL WINDOW GLASS SCRATCH - BUILT ON OR BEFORE 8/13/2010 FORD: 2008-2011 Escape MERCURY: 2008-2011 Mariner This article supersedes TSB 10-25-5 to update the Part List. ISSUE Some 2008-2011 Escape and Mariner vehicles built on or before 8/13/2010 may exhibit a front and/or rear window glass squeak noise with or without side window vertical window glass scratch. This may be due to a tolerance stack up condition and/or incorrect door flange adjustment. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Fully lower the affected window glass. 2. Remove the exterior door glass weatherstrip. Refer to Workshop Manual (WSM), Section 501-11 (Exploded View). 3. Fully raise the window glass. 4. Measure the distance from the inside edge of the weatherstrip flange to the outside sur[ace of the window glass. Is the distance within specification range of 1/4" (6 mm) to 3/8" (10 mm)? a. Yes - Proceed to Step 5. b. No - Using a suitable tool, evenly adjust the flange into specification. Proceed to Step 5. 5. Inspect the side window glass for evidence of vertical scratches. Are scratches present? a. Yes - Replace the affected side window glass and exterior door glass weatherstrip. Refer to WSM, Section 501-11. b. No - Replace the affected exterior door glass weatherstrip. Refer to WSM, Section 501-11. 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 110215A 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 110215B 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 7429 With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215C 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215D 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors 110215E 2008-2011 Escape, 0.5 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 11021SF 2008-2011 Escape, 1.0 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215G 2008-2011 Escape, 0.8 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215H 2008-2011 Escape, 1.5 Hrs. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 7821453 41 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 7430 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass Weatherstrip: > 10-25-4 > Dec > 10 > Body - Front Door Window Exterior Weatherstrip Deformed Front Door Window Glass Weatherstrip: All Technical Service Bulletins Body - Front Door Window Exterior Weatherstrip Deformed TSB 10-25-4 12/23/10 FRONT EXTERIOR DOOR GLASS WEATHERSTRIP DEFORMED OR LIFTING - BUILT ON OR BEFORE 517/2010 12/23/10 FORD: 008-2010 Escape MERCURY: 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 5/7/2010 may exhibit the front exterior door glass weatherstrip deformed and/or lifting up from the door flange. This may be due to a lack of retention between the door glass weatherstrip and flange. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove affected front exterior door glass weatherstrip. Reference Workshop Manual (WSM), Section 501-11 Glass, Frames, and Mechanisms Exploded View. 2. Apply a strip of 3M(TM) Safety-Walk(TM) Slip-Resistant General Purpose Tapes, or similar (obtained locally) to the outer flange surface at the center of the door. Cut grip tape to approximately 2.5" X .5" (64 mm X 13 mm). (Figure 1) 3. Install new revised exterior door glass weatherstrip. Reference WSM, Section 501-11 Glass, Frames, and Mechanisms - Exploded View. 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 102504A 2008-2010 Escape, 0.2 Hr. Mariner: Replace One Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass Weatherstrip: > 10-25-4 > Dec > 10 > Body - Front Door Window Exterior Weatherstrip Deformed > Page 7435 Exterior Door Glass Weather Strip Includes Time To Install Grip Tape (Do Not Use With Any Other Labor Operations) 102504B 2008-2010 Escape, 0.3 Hr. Mariner: Replace Both Exterior Door Glass Weather Strips Includes Time To Install Grip Tape (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7821453 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door Front Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Front Door Glass, Frames and Mechanisms - Exploded View, Front Door 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 7438 Front Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Front Door Glass Top Run - Front Removal and Installation 1. Remove the front door window glass. For additional information, refer to Window Glass - Front Door See: Doors, Hood and Trunk/Doors/Front Door/Front Door Window Glass/Service and Repair/Window Glass - Front Door. 2. Remove the front door interior sail panel. - If equipped, disconnect the speaker electrical connector. 3. Remove the 2 front door glass top run bolts. - To install tighten to 6 Nm (53 lb-in). 4. Remove the front door glass top run. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched Rear Door Window Glass Weatherstrip: Customer Interest Body - Front/Rear Door Window Noise/Glass Scratched TSB 11-2-15 02/28/11 WINDOW SQUEAK NOISE AND/OR VERTICAL WINDOW GLASS SCRATCH - BUILT ON OR BEFORE 8/13/2010 FORD: 2008-2011 Escape MERCURY: 2008-2011 Mariner This article supersedes TSB 10-25-5 to update the Part List. ISSUE Some 2008-2011 Escape and Mariner vehicles built on or before 8/13/2010 may exhibit a front and/or rear window glass squeak noise with or without side window vertical window glass scratch. This may be due to a tolerance stack up condition and/or incorrect door flange adjustment. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Fully lower the affected window glass. 2. Remove the exterior door glass weatherstrip. Refer to Workshop Manual (WSM), Section 501-11 (Exploded View). 3. Fully raise the window glass. 4. Measure the distance from the inside edge of the weatherstrip flange to the outside sur[ace of the window glass. Is the distance within specification range of 1/4" (6 mm) to 3/8" (10 mm)? a. Yes - Proceed to Step 5. b. No - Using a suitable tool, evenly adjust the flange into specification. Proceed to Step 5. 5. Inspect the side window glass for evidence of vertical scratches. Are scratches present? a. Yes - Replace the affected side window glass and exterior door glass weatherstrip. Refer to WSM, Section 501-11. b. No - Replace the affected exterior door glass weatherstrip. Refer to WSM, Section 501-11. 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 110215A 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 110215B 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 7447 With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215C 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215D 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors 110215E 2008-2011 Escape, 0.5 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 11021SF 2008-2011 Escape, 1.0 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215G 2008-2011 Escape, 0.8 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215H 2008-2011 Escape, 1.5 Hrs. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 7821453 41 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 7448 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched Rear Door Window Glass Weatherstrip: All Technical Service Bulletins Body - Front/Rear Door Window Noise/Glass Scratched TSB 11-2-15 02/28/11 WINDOW SQUEAK NOISE AND/OR VERTICAL WINDOW GLASS SCRATCH - BUILT ON OR BEFORE 8/13/2010 FORD: 2008-2011 Escape MERCURY: 2008-2011 Mariner This article supersedes TSB 10-25-5 to update the Part List. ISSUE Some 2008-2011 Escape and Mariner vehicles built on or before 8/13/2010 may exhibit a front and/or rear window glass squeak noise with or without side window vertical window glass scratch. This may be due to a tolerance stack up condition and/or incorrect door flange adjustment. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Fully lower the affected window glass. 2. Remove the exterior door glass weatherstrip. Refer to Workshop Manual (WSM), Section 501-11 (Exploded View). 3. Fully raise the window glass. 4. Measure the distance from the inside edge of the weatherstrip flange to the outside sur[ace of the window glass. Is the distance within specification range of 1/4" (6 mm) to 3/8" (10 mm)? a. Yes - Proceed to Step 5. b. No - Using a suitable tool, evenly adjust the flange into specification. Proceed to Step 5. 5. Inspect the side window glass for evidence of vertical scratches. Are scratches present? a. Yes - Replace the affected side window glass and exterior door glass weatherstrip. Refer to WSM, Section 501-11. b. No - Replace the affected exterior door glass weatherstrip. Refer to WSM, Section 501-11. 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 110215A 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 110215B 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 7454 With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215C 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215D 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors 110215E 2008-2011 Escape, 0.5 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 11021SF 2008-2011 Escape, 1.0 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215G 2008-2011 Escape, 0.8 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215H 2008-2011 Escape, 1.5 Hrs. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 7821453 41 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Glass Weatherstrip: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 7455 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear Rear Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Rear Door Glass Top Run - Rear Removal and Installation 1. Remove the rear door window regulator. For additional information, refer to Window Regulator Rear Door See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Window Regulator/Service and Repair/Window Regulator Rear Door. 2. Position the rear door window glass to the full DOWN position. 3. Remove the 2 screws and the rear door exterior sail panel. 4. Remove the interior door glass weatherstrip. 5. Remove the exterior door glass weatherstrip. 6. Remove the rear door glass top run bolt. - To install, tighten to 6 Nm (53 lb-in). 7. Position the rear door window glass down and forward. 8. Remove the rear door glass top run. 9. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear > Page 7458 Rear Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Rear Door Glass, Frames and Mechanisms - Exploded View, Rear Door 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 7463 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch Cruise Control Switch: Service and Repair Speed Control Switch Speed Control Switch Escape and Mariner shown, Hybrid similar Removal and Installation 1. Remove the speed control switch by pulling the switch toward the rear of the vehicle. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch > Page 7468 Cruise Control Switch: Service and Repair Speed Control Deactivator Switch Speed Control Deactivator Switch Removal and Installation 1. Disconnect the electrical connector. 2. Rotate the speed control deactivator switch counterclockwise one-quarter turn. 3. Remove the speed control deactivator switch. 4. NOTE: When installing the speed control deactivator switch, it is automatically self-adjusting to the correct position. Do not pull up or push down on the pedal during installation. Initial installation of the speed control deactivator switch allows for one adjustment. If additional adjustments are necessary, install a new switch. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 7473 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch Cruise Control Switch: Service and Repair Speed Control Switch Speed Control Switch Escape and Mariner shown, Hybrid similar Removal and Installation 1. Remove the speed control switch by pulling the switch toward the rear of the vehicle. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch > Page 7478 Cruise Control Switch: Service and Repair Speed Control Deactivator Switch Speed Control Deactivator Switch Removal and Installation 1. Disconnect the electrical connector. 2. Rotate the speed control deactivator switch counterclockwise one-quarter turn. 3. Remove the speed control deactivator switch. 4. NOTE: When installing the speed control deactivator switch, it is automatically self-adjusting to the correct position. Do not pull up or push down on the pedal during installation. Initial installation of the speed control deactivator switch allows for one adjustment. If additional adjustments are necessary, install a new switch. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams > Page 7482 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Brake Booster Travel Sensor - Hybrid Removal and Installation 1. Disconnect the brake booster travel sensor electrical connector. 2. Release the brake booster travel sensor retainer ring and remove the travel sensor. 3. To install, reverse the removal procedure. 4. Following the scan tool instructions, carry out the multi-calibration routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Diagrams > Page 7486 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Brake Booster Travel Sensor - Hybrid Removal and Installation 1. Disconnect the brake booster travel sensor electrical connector. 2. Release the brake booster travel sensor retainer ring and remove the travel sensor. 3. To install, reverse the removal procedure. 4. Following the scan tool instructions, carry out the multi-calibration routine. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Service and Repair Air Bag Deactivation Indicator: Service and Repair Passenger Air Bag Deactivation (PAD) Indicator NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: The Passenger Air Bag Deactivation (PAD) indicator is part of the upper instrument panel center finish panel. 1. NOTE: The ignition must be in the OFF position before disconnecting the PAD indicator electrical connector. Otherwise, a DTC will be set in the Restraints Control Module (RCM) memory and must be cleared before releasing the vehicle to the customer. Turn the ignition OFF and wait at least one minute. 2. NOTE: The passenger air bag module is not shown for clarity. Open and lower the glove compartment door to gain access to the PAD indicator electrical connector. - Disconnect the PAD indicator electrical connector. 3. Pull out to release the retaining clips and detach the instrument panel upper center finish panel. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7495 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7496 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7497 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7498 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7499 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7500 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7501 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7502 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7503 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7504 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7505 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7506 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7507 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7508 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7509 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7510 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7511 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7512 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7513 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7514 Cigarette Lighter: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 44-1 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7515 Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation Compass: Description and Operation Electronic Compass The compass display is incorporated into the Front Display Interface Module (FDIM) for vehicles without navigation. For vehicles with navigation, the compass display is incorporated into the Audio Control Module (ACM). Refer to Radio, Stereo, and Compact Disc. Vehicles With Navigation The compass signal originates from the Global Positioning System (GPS) antenna. No calibration or zone adjustment is available, as the compass heading is based on the GPS signal. Refer to Radio, Stereo, and Compact Disc. The vehicle heading is displayed as a 1 or 2 character display located in the ACM and indicates the current direction of the vehicle (N, NE, E, SE, S, SW, W, or NW). Vehicles Without Navigation The compass signal originates from the compass module, which is integrated into the interior rear view mirror. Refer to Mirrors. The vehicle heading is displayed as a 1 or 2 character display located in the lower LH side of the FDIM and indicates the current direction of the vehicle (N, NE, E, SE, S, SW, W, or NW). The compass continuously re-calibrates due to changes in the magnetic field and remains accurate during most driving conditions. All Vehicles The MODE button that allows the driver to operate the calibration and zone setting procedures is located on the center bottom of the interior rear view mirror. The compass display is on with the key in the ON or START positions. When the key is first turned to the ON or START position, there is a momentary delay of approximately 6 seconds before the compass display illuminates. If the battery saver has been activated and the key is turned to ON or START, the momentary delay before the compass display illuminates is approximately 3 seconds. The compass display will turn off as soon as the key is turned to the OFF or ACC position. Compass Accuracy (without Navigation) Driving near power lines, or driving in the area of large iron or steel structures can temporarily change the compass heading. If the compass remains inaccurate after driving near such objects, calibrate the compass. Refer to Compass Calibration See: Adjustments/Compass Calibration. Most geographic areas (zones) have a magnetic north compass point that varies slightly from the northerly direction on maps. This variation is 4 degrees between the adjacent zones and becomes noticeable as the vehicle crosses multiple zones. A correct zone setting eliminates the error. Refer to Compass Zone Adjustment See: Adjustments/Compass Zone Adjustment. Compass Accuracy (with Navigation) Driving near power lines, or driving in the area of large iron or steel structures have no effect on the compass heading. Compass calibration and compass zone setting procedures are not required if the vehicle is equipped with navigation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Compass: Initial Inspection and Diagnostic Overview Special Tools Used With Diagnostics Electronic Compass Inspection And Verification Electronic Compass Inspection and Verification NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC). 5. NOTE: The Vehicle Communication Module (VCM) prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: - Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus, No Power To The Scan Tool, to diagnose no power to the scan tool. 6. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus to diagnose no response from the PCM. 7. Carry out the network test. - If the scan tool responds with no communication for one or more modules, refer to Information Bus. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7521 - If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the FDIM and the Instrument Cluster (IC). 9. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart in Body Control Systems. See: Diagnostic Trouble Code Descriptions See: Body and Frame/Body Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7522 Compass: Diagnostic Trouble Code Descriptions Electronic Compass DTC Charts B2097 / U2013 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7523 Compass: Symptom Related Diagnostic Procedures Electronic Compass Symptom Chart Symptom Chart Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7524 Compass: Pinpoint Tests Pinpoint Test A: The Compass Is Inoperative Electronic Compass Pinpoint Tests Pinpoint Test A: The Compass Is Inoperative Refer to Wiring Diagram Set 130 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Audio System/Navigation for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number NOTE: This pinpoint test is for vehicles without navigation. For vehicles with navigation, refer to Radio, Stereo, and Compact Disc. Normal Operation The compass display (located in the Front Display Interface Module (FDIM)) receives battery voltage from the Smart Junction Box (SJB) fuse 14 (10A) through circuit SBP14 (BN/RD). Ground for the FDIM is supplied through circuit GD114 (BK/BU). The compass module provides vehicle directional inputs to the Instrument Cluster (IC), which sends the compass information to the FDIM over the Medium Speed Controller Area Network (MS-CAN). The FDIM will display the compass direction according to the information that has been provided by the compass module to the IC. - DTC B2097 (Compass Module Failure) - sets when the IC attempts a self-test of the compass module and its associated circuits and a failure results. - DTC U2013 (Compass Module is Not Responding) - sets when the IC does not receive any communications from the compass module. This pinpoint test is intended to diagnose the following: - Fuses - Wiring, terminals or connectors - Compass module - FDIM (compass display) - IC PINPOINT TEST A: THE COMPASS IS INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- A1 CHECK THE COMPASS DISPLAY - Ignition ON. - Check the compass display. - Does the compass display illuminate? Yes If the compass display illuminates with only 2 bars, GO to A3. If the compass display turns on, but it does not display all directions, or indicates CAL, Go To Pinpoint Test b. See: Pinpoint Test B: The Compass Is Inaccurate No GO to A2. ------------------------------------------------- A2 CHECK THE VEHICLE CONFIGURATION - Verify the vehicle is equipped with the compass feature. - Is the vehicle equipped with the compass feature? Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7525 Yes REFER to Radio, Stereo, and Compact Disc to diagnose the FDIM display. No RETURN the vehicle to the customer and ADVISE them the vehicle is not equipped with a compass display feature. ------------------------------------------------- A3 CHECK CIRCUIT CBP41 (BU) FOR VOLTAGE - Ignition OFF. - Disconnect: Interior Rear View Mirror C9012. - Ignition ON. - Measure the voltage between the interior rear view mirror C9012-1, circuit CBP41 (BU), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to A4. No VERIFY the SJB fuse 41 (15A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. ------------------------------------------------- A4 CHECK CIRCUIT GD182 (BK/GY) FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the interior rear view mirror C9012-3, circuit GD182 (BK/GY), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to A5. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. ------------------------------------------------- A5 CHECK CIRCUIT VMC31 (YE/GN) FOR AN OPEN OR A SHORT TO GROUND - Disconnect: Interior Rear View Mirror C9012. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7526 - Disconnect: IC C220. - Measure the resistance between the interior rear view mirror C9012-6, circuit VMC31 (YE/GN), harness side and the IC C220-16, circuit VMC31 (YE/GN), harness side; and between the interior rear view mirror C9012-6, circuit VMC31 (YE/GN), harness side and ground. - Is the resistance less than 5 ohms between the interior rear view mirror and the IC, and greater than 10,000 ohms between the interior rear view mirror and ground? Yes GO to A6. No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- A6 CHECK CIRCUIT VMC30 (BU/GY) FOR AN OPEN OR A SHORT TO GROUND - Measure the resistance between the interior rear view mirror C9012-7, circuit VMC30 (BU/GY), harness side and the IC C220-17, circuit VMC30 (BU/GY), harness side; and between the interior rear view mirror C9012-7, circuit VMC30 (BU/GY), harness side and ground. - Is the resistance less than 5 ohms between the interior rear view mirror and the IC, and greater than 10,000 ohms between the interior rear view mirror and ground? Yes GO to A7. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- A7 CHECK FOR DTC U2013 - Connect: Negative Battery Cable. - Connect: IC C220. - Connect: Interior Rear View Mirror C9012. - Ignition ON. - Clear the DTCs. - Ignition OFF. - Ignition ON. - Wait 10 seconds. - Retrieve the IC DTCs. - Is DTC U2013 present? Yes INSTALL a new interior rear view mirror. ADJUST the zone setting. REFER to Compass Zone Adjustment See: Adjustments/Compass Zone Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7527 Adjustment. CALIBRATE the compass. REFER to Compass Calibration See: Adjustments/Compass Calibration. TEST the system for normal operation. No GO to A8. ------------------------------------------------- A8 CHECK FOR CORRECT IC OPERATION - Disconnect the IC connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the IC connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new IC. RESET the parameters in both the IC and the PCM. REFER to Antitheft and Alarm Systems. PROGRAM the PATS keys into the new IC. REFER to Antitheft and Alarm Systems. CYCLE the ignition. REPEAT the self-test. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. CYCLE the ignition. REPEAT the self-test. TEST the system for normal operation. ------------------------------------------------Pinpoint Test B: The Compass Is Inaccurate Electronic Compass Pinpoint Tests Pinpoint Test B: The Compass Is Inaccurate NOTE: This pinpoint test is for vehicles without navigation. For vehicles with navigation, refer to Radio, Stereo, and Compact Disc. Normal Operation The compass display (located in the Front Display Interface Module (FDIM)) receives battery voltage from the Smart Junction Box (SJB) fuse 14 (10A) through circuit SBP14 (BN/RD). Ground for the compass display is supplied through circuit GD114 (BK/BU). The compass module (integral to the interior rear view mirror) provides vehicle directional inputs to the Instrument Cluster (IC), which sends the compass information to the FDIM over the Medium Speed Controller Area Network (MS-CAN). The FDIM will display the compass direction according to the information that has been provided by the compass module to the IC. This pinpoint test is intended to diagnose the following: - Magnetized vehicle - Compass zone setting - Compass calibration - Compass module PINPOINT TEST B: THE COMPASS IS INACCURATE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. ------------------------------------------------- B1 DEMAGNETIZE THE VEHICLE - Demagnetize the vehicle. Refer to Vehicle Demagnetizing See: Adjustments/Vehicle Demagnetizing. - Does the compass operate correctly? Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7528 Yes The compass is OK. The concern may have been caused by an incorrect zone setting, a magnetized vehicle, or the compass was out of calibration. No GO to B2. ------------------------------------------------- B2 CHECK THE COMPASS ACCURACY - Position the vehicle and observe the compass display as follows: - Does the compass display as indicated? Yes The compass is OK. The concern may have been caused by an incorrect zone setting, a magnetized vehicle, or the compass was out of calibration. No INSTALL a new compass module. SET the zone. REFER to Compass Zone Adjustment See: Adjustments/Compass Zone Adjustment. CALIBRATE the compass. REFER to Compass Calibration See: Adjustments/Compass Calibration. TEST the system for normal operation. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment Compass: Adjustments Compass Zone Adjustment Compass Zone Adjustment 1. Refer to the compass calibration zone map to select the correct compass zone setting for the geographic location of the vehicle. 2. With the ignition in the ON position, press and hold the MODE button (for approximately 5 seconds) until the display shows the current zone setting. Release the MODE button. 3. NOTE: After approximately 5 seconds, the compass display will exit the zone setting mode after the button has been released. Before the zone setting mode turns off (within 5 seconds), momentarily press and release the MODE button to increase the zone increment by one. Set the zone display number to match the vehicle geographical location on the compass calibration zone map. 4. Release the switch for 5 seconds to exit the zone setting mode. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment > Page 7531 Compass: Adjustments Vehicle Demagnetizing Vehicle Demagnetizing NOTICE: During demagnetizing, the demagnetizer coil pulls toward the vehicle. Place a cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. NOTE: The demagnetizing process requires the use of a demagnetizing coil commonly used by television repair technicians to demagnetize television tubes. NOTE: To demagnetize, use a constant circular motion over the vehicle roof. Do not turn off the demagnetizer while sweeping the vehicle roof to prevent remagnetizing ferrous materials contained in the vehicle. NOTE: During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite the handle) is closest to the vehicle surface. 1. Demagnetize the front third of the vehicle roof. 1. Turn on the demagnetizer at least 1 m (3 ft) away from the vehicle. 2. Holding the demagnetizer no more than 2.5 cm (1 in) from the vehicle roof and starting on the passenger side, demagnetize the front third of the vehicle roof closest to the windshield using a constant circular motion. Keep the circle radius within 30 cm (12 in) while sweeping across the entire surface of the vehicle roof closest to the windshield. Continue the circular motion 4 times. 3. After the fourth pass and without stopping, move the demagnetizer at least 1 m (3 ft) away from the vehicle. 4. Turn the demagnetizer off. 2. Carry out the compass zone adjustment procedure. For additional information, refer to Compass Zone Adjustment See: Compass Zone Adjustment. 3. Carry out the compass calibration adjustment procedure. For additional information, refer to Compass Calibration See: Compass Calibration. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment > Page 7532 Compass: Adjustments Compass Calibration Compass Calibration NOTE: This procedure is applicable only to vehicles not equipped with navigation. 1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (heated rear window, heater fan, A/C, map lamps, and wipers) and make sure all doors are closed. Start the vehicle. 2. NOTE: It is not possible to exit the CAL mode unless the vehicle is driven in circles. NOTE: While holding the MODE button down, the compass display will first enter the ZONE setting mode (after 5 seconds) and then after another 5 seconds (10 seconds total), the compass display will enter the CAL mode. Press and hold (for approximately 10 seconds) the MODE button until CAL appears in the display, then release the MODE button. 3. NOTE: If the CAL indicator does not turn off after the vehicle is driven in a circle at least 5 times, repeat the procedure. Drive the vehicle slowly at less than 5 km/h (3 mph) in a continuous circle until CAL disappears from the display and the compass heading is shown. 4. If the CAL message does not turn off within 5 circles (and the procedure has been repeated at least once), install a new compass module (integral to the interior rear view mirror). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering Supplemental Restraint System (SRS) Depowering and Repowering Depowering Procedure WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 OFF. 3. At the Smart Junction Box (SJB), located at the RH side of the center console, remove the cover and the RCM fuse 32 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition from OFF to ON. 2. Install RCM fuse 32 (10A) to the SJB and install the cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7538 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 4. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the 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 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7539 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 to OFF. 3. At the Smart Junction Box (SJB) located at the RH side of the center console, remove the cover and the RCM fuse 32 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Using a 3-mm Allen wrench or a suitable tool, place it in the driver air bag module release hole on the underside of the steering wheel. 8. NOTICE: During driver air bag module removal, make sure all 3 driver air bag module hooks are released from the steering wheel wire Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7540 clip. Failure to do so may cause damage to the driver air bag module and or the steering wheel. NOTE: The driver air bag module is removed for clarity. Position the 3-mm Allen wrench or suitable tool against the wire clip and push inward disengaging the wire clip from the 3 driver air bag module hooks. 9. Disconnect the horn electrical connector. Then disconnect the 2 driver air bag module electrical connectors and remove the driver air bag module. 10. Open and lower the glove compartment door. 11. Remove the 2 passenger air bag module bolts. 12. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Failure to follow this instruction may result in vehicle damage, equipment damage, component damage and/or system failure. NOTE: Use care when removing the passenger air bag module from the instrument panel. The passenger air bag module can drop down during removal and the passenger air bag module rear bracket can scratch the front of the instrument panel. Through the glove compartment opening, release the passenger air bag module deployment door clips while pushing the passenger air bag module out of the instrument panel. 13. Remove the passenger air bag module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7541 1. Disconnect the 2 passenger air bag module electrical connectors. 2. Detach the wire harness routing clip and remove the passenger air bag module. 14. From under the rear of the passenger seat, slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 15. Remove the passenger side D-pillar trim panel. 1. Separate the weatherstrip. 2. Pull out and separate the quarter trim panel at the D-pillar trim panel. 3. Pull out to release the retainers and remove the D-pillar trim panel. 16. Disconnect the passenger side safety canopy module electrical connector. 17. Remove the driver side D-pillar trim panel. 1. Separate the weatherstrip. 2. Pull out and separate the quarter trim panel at the D-pillar trim panel. 3. Pull out to release the retainers and remove the D-pillar trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7542 18. Disconnect the driver side safety canopy module electrical connector. 19. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 20. Install RCM fuse 32 (10A) to the SJB. 21. Connect the battery ground cable. Reactivation 1. Remove RCM fuse 32 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 4. Connect the driver side safety canopy module electrical connector. 5. Install the driver side D-pillar trim panel. 1. Engage the D-pillar trim panel to the quarter trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7543 2. Install the D-pillar trim panel. 3. Install the weatherstrip. 6. Connect the passenger side safety canopy module electrical connector. 7. Install the passenger side D-pillar trim panel. 1. Engage the D-pillar trim panel to the quarter trim panel. 2. Install the D-pillar trim panel. 3. Install the weatherstrip. 8. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 9. NOTICE: During passenger air bag module installation, make sure the passenger air bag module wire harness routing clip is attached to the passenger air bag module. Failure to follow this instruction may result in wiring harness damage. NOTICE: The passenger air bag module electrical connectors are unique and cannot be reversed when connected to the passenger air bag module. Match the electrical connector key to the keyway in the passenger air bag module. Do not force the electrical connectors into the passenger air bag module. Failure to follow these instructions may result in component and/or connector damage. Install the passenger air bag module. 1. Connect the 2 passenger air bag module electrical connectors. 2. Attach the wire harness routing clip. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7544 10. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Failure to follow this instruction may result in vehicle damage, equipment damage, component damage and/or system failure. NOTE: During passenger air bag module installation, make sure all the deployment door clips are fully seated into the instrument panel. NOTE: Use care when installing the passenger air bag module in the instrument panel. The passenger air bag module rear bracket can scratch the front of the instrument panel. Position the passenger air bag module and seat the passenger air bag module deployment door clips into the instrument panel. 11. Install the 2 passenger air bag module bolts. - To install, tighten to 8 Nm (71 lb-in). 12. Close the glove compartment door. 13. Install the driver air bag module electrical connectors fully into the driver air bag module. Then connect the horn electrical connector. 14. NOTE: Make sure the driver air bag module wiring harness is routed down and away from the driver air bag module hooks during installation. NOTE: Audible clicks will be heard when the 3 wire clips are seated in the 3 driver air bag module hooks. Align the driver air bag module hooks to the steering wheel and, while pushing inward, seat the 3 driver air bag module hooks to the steering wheel wire clip. - When the 3 driver air bag module hooks are seated in place, gently pull outward at the corners of the driver air bag module to make sure that the 3 hooks are fully seated. There should also be an even gap between the driver air bag module trim cover and the steering wheel. Check the driver air bag module and trim cover for correct movement when applying the horn. 15. Turn the ignition switch from OFF to ON. 16. Install RCM fuse 32 (10A) to the SJB and install the cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7545 17. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 18. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair Instrument Panel Dimmer Switch Removal and Installation 1. Remove the Instrument Cluster (IC) finish panel. 2. NOTE: The instrument panel dimmer switch is removed by releasing the tabs and pulling from behind. Release the tabs and remove the instrument panel dimmer switch assembly. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 7552 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 7556 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Reset Procedure Driver/Vehicle Information Display: Reset Procedure Oil Life Reset Message Center Configuration Oil Life Reset NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: The XXX's in the steps below represent a numeric value and will display the correct number in percent. For example; OIL LIFE = XXX% may display OIL LIFE = 45%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3. The message center displays OIL LIFE SET TO 100%. Oil Life Start Value Message Center Configuration Oil Life Start Value NOTE: The oil life start value is used to reset the oil life value back to the maximum of approximately 12,000 km (7,500 miles) if the value was previously changed or to lower the value by 10% increments down to 10%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release to adjust new oil life %. 3. NOTE: Once the percent has been lowered to 10%, the next button press starts the sequence over again beginning at 100%. Press and release the RESET button to lower the start value percent until the message center displays the newly desired percent. 4. Press and release the SETUP button to return to the setup menu. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Reset Procedure > Page 7559 Driver/Vehicle Information Display: Removal and Replacement Message Center Switch Removal and Installation All vehicles 1. Remove the LH instrument panel trim panel. Hybrid vehicles 2. Remove the jump start switch screw and position the jump start switch aside. All vehicles 3. Press the retaining tabs and remove the message center switch. - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 7563 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Gauge Sender: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Fuel Tank Filler Pipe Assembly Fuel Tank and Fuel Pump (FP) module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 7566 Fuel Tank Supports Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 7567 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 7568 Fuel Gauge Sender: Service and Repair Fuel Pump Module Fuel Pump Module Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the Fuel Pump (FP) module access cover. 4. NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material. Disconnect the FP module electrical connector. 5. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage. Disconnect the fuel tube-to-FP module quick connect coupling. 6. Disconnect the fuel tank filler pipe recirculation tube-to-FP module quick connect coupling. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 7569 7. NOTE: For initial fuel draining, it is required to remove the fuel through the fuel tank filler pipe recirculation tube port on the FP module. Connect the Fuel Storage Tanker to the fuel tank filler pipe recirculation tube port on the FP module and remove approximately one-fourth of the fuel (from a completely full tank), lowering the fuel level below the FP module mounting flange. 8. NOTICE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP module when removing the lock ring. NOTE: When installing the FP module, install a new O-ring seal. Install the Fuel Tank Sender Unit Wrench and remove the FP module lock ring. 9. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm. NOTE: Some residual fuel may remain in the FP module. Carefully drain into a suitable container. Completely remove the FP module from the fuel tank. 10. NOTE: Inspect the surfaces of the FP module flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded. NOTE: To install, apply clean engine oil to the O-ring seal. Remove and discard the FP module O-ring seal. 11. NOTE: Make sure to install a new FP module O-ring seal and lock ring. To install, reverse the removal procedure. Make sure the alignment arrows on the FP module and the fuel tank meet before tightening the FP module lock ring. - Tighten the FP lock ring until it meets the stop tabs on the fuel tank. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering Supplemental Restraint System (SRS) Depowering and Repowering Depowering Procedure WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 OFF. 3. At the Smart Junction Box (SJB), located at the RH side of the center console, remove the cover and the RCM fuse 32 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition from OFF to ON. 2. Install RCM fuse 32 (10A) to the SJB and install the cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7575 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 4. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the 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 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7576 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 to OFF. 3. At the Smart Junction Box (SJB) located at the RH side of the center console, remove the cover and the RCM fuse 32 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Using a 3-mm Allen wrench or a suitable tool, place it in the driver air bag module release hole on the underside of the steering wheel. 8. NOTICE: During driver air bag module removal, make sure all 3 driver air bag module hooks are released from the steering wheel wire Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7577 clip. Failure to do so may cause damage to the driver air bag module and or the steering wheel. NOTE: The driver air bag module is removed for clarity. Position the 3-mm Allen wrench or suitable tool against the wire clip and push inward disengaging the wire clip from the 3 driver air bag module hooks. 9. Disconnect the horn electrical connector. Then disconnect the 2 driver air bag module electrical connectors and remove the driver air bag module. 10. Open and lower the glove compartment door. 11. Remove the 2 passenger air bag module bolts. 12. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Failure to follow this instruction may result in vehicle damage, equipment damage, component damage and/or system failure. NOTE: Use care when removing the passenger air bag module from the instrument panel. The passenger air bag module can drop down during removal and the passenger air bag module rear bracket can scratch the front of the instrument panel. Through the glove compartment opening, release the passenger air bag module deployment door clips while pushing the passenger air bag module out of the instrument panel. 13. Remove the passenger air bag module. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7578 1. Disconnect the 2 passenger air bag module electrical connectors. 2. Detach the wire harness routing clip and remove the passenger air bag module. 14. From under the rear of the passenger seat, slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 15. Remove the passenger side D-pillar trim panel. 1. Separate the weatherstrip. 2. Pull out and separate the quarter trim panel at the D-pillar trim panel. 3. Pull out to release the retainers and remove the D-pillar trim panel. 16. Disconnect the passenger side safety canopy module electrical connector. 17. Remove the driver side D-pillar trim panel. 1. Separate the weatherstrip. 2. Pull out and separate the quarter trim panel at the D-pillar trim panel. 3. Pull out to release the retainers and remove the D-pillar trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7579 18. Disconnect the driver side safety canopy module electrical connector. 19. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 20. Install RCM fuse 32 (10A) to the SJB. 21. Connect the battery ground cable. Reactivation 1. Remove RCM fuse 32 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 4. Connect the driver side safety canopy module electrical connector. 5. Install the driver side D-pillar trim panel. 1. Engage the D-pillar trim panel to the quarter trim panel. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7580 2. Install the D-pillar trim panel. 3. Install the weatherstrip. 6. Connect the passenger side safety canopy module electrical connector. 7. Install the passenger side D-pillar trim panel. 1. Engage the D-pillar trim panel to the quarter trim panel. 2. Install the D-pillar trim panel. 3. Install the weatherstrip. 8. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 9. NOTICE: During passenger air bag module installation, make sure the passenger air bag module wire harness routing clip is attached to the passenger air bag module. Failure to follow this instruction may result in wiring harness damage. NOTICE: The passenger air bag module electrical connectors are unique and cannot be reversed when connected to the passenger air bag module. Match the electrical connector key to the keyway in the passenger air bag module. Do not force the electrical connectors into the passenger air bag module. Failure to follow these instructions may result in component and/or connector damage. Install the passenger air bag module. 1. Connect the 2 passenger air bag module electrical connectors. 2. Attach the wire harness routing clip. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7581 10. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Failure to follow this instruction may result in vehicle damage, equipment damage, component damage and/or system failure. NOTE: During passenger air bag module installation, make sure all the deployment door clips are fully seated into the instrument panel. NOTE: Use care when installing the passenger air bag module in the instrument panel. The passenger air bag module rear bracket can scratch the front of the instrument panel. Position the passenger air bag module and seat the passenger air bag module deployment door clips into the instrument panel. 11. Install the 2 passenger air bag module bolts. - To install, tighten to 8 Nm (71 lb-in). 12. Close the glove compartment door. 13. Install the driver air bag module electrical connectors fully into the driver air bag module. Then connect the horn electrical connector. 14. NOTE: Make sure the driver air bag module wiring harness is routed down and away from the driver air bag module hooks during installation. NOTE: Audible clicks will be heard when the 3 wire clips are seated in the 3 driver air bag module hooks. Align the driver air bag module hooks to the steering wheel and, while pushing inward, seat the 3 driver air bag module hooks to the steering wheel wire clip. - When the 3 driver air bag module hooks are seated in place, gently pull outward at the corners of the driver air bag module to make sure that the 3 hooks are fully seated. There should also be an even gap between the driver air bag module trim cover and the steering wheel. Check the driver air bag module and trim cover for correct movement when applying the horn. 15. Turn the ignition switch from OFF to ON. 16. Install RCM fuse 32 (10A) to the SJB and install the cover. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7582 17. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 18. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back ON and monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 08-23-12 > Nov > 08 > Temperature Display - Toggles From Fahrenheit To Celsius Instrument Panel Control Module: Customer Interest Temperature Display - Toggles From Fahrenheit To Celsius TSB 08-23-12 11/24/08 FRONT DISPLAY INTERFACE MODULE (FDIM) - OUTSIDE TEMPERATURE DISPLAY TOGGLES BETWEEN FAHRENHEIT/CELSIUS FORD: 2008-2009 Escape Hybrid, Escape MERCURY: 2008-2009 Mariner Hybrid, Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles may exhibit an outside temperature display in the FDIM that toggles between Fahrenheit and Celsius. ACTION Reprogram the Instrument Cluster module to the latest calibration using IDS release 57.9 and higher with patch 13 or 58.2 and higher. This new calibration is not included in the VCM 2008.11 DVD. Calibration and IDS patch files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 082312A 2008-2009 Escape, 0.3 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Reprogram The Instrument Cluster, Authorization Decal Not Required.(Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 08-23-12 > Nov > 08 > Temperature Display - Toggles From Fahrenheit To Celsius Instrument Panel Control Module: All Technical Service Bulletins Temperature Display - Toggles From Fahrenheit To Celsius TSB 08-23-12 11/24/08 FRONT DISPLAY INTERFACE MODULE (FDIM) - OUTSIDE TEMPERATURE DISPLAY TOGGLES BETWEEN FAHRENHEIT/CELSIUS FORD: 2008-2009 Escape Hybrid, Escape MERCURY: 2008-2009 Mariner Hybrid, Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles may exhibit an outside temperature display in the FDIM that toggles between Fahrenheit and Celsius. ACTION Reprogram the Instrument Cluster module to the latest calibration using IDS release 57.9 and higher with patch 13 or 58.2 and higher. This new calibration is not included in the VCM 2008.11 DVD. Calibration and IDS patch files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 082312A 2008-2009 Escape, 0.3 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Reprogram The Instrument Cluster, Authorization Decal Not Required.(Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) The MIL alerts the driver that the powertrain control module (PCM) has detected an on board diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD diagnostic trouble code (DTC) is set. - The MIL is located on the instrument cluster and is labeled as International Standards Organization (ISO) engine symbol. - Power is supplied to the MIL whenever the key is in the ON or START position. - The MIL remains on in the on/start mode as a bulb check during the instrument cluster prove-out 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 is set. - the instrument cluster illuminates 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). - If the MIL remains off during the bulb check, there is: an instrument cluster concern. - an instrument cluster wiring concern. - 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 concern. - For any MIL concern, refer to Symptom Charts, GO to Quick Test QT1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/QT : Powertrain Control Module (PCM)/Transaxle Control Module (TCM) Quick Test . - If the MIL blinks at a steady rate, a severe misfire condition may exist. - The MIL flashes after a period of time with the key in the RUN position (engine not running) if DTC P1000 is set. ISO Standard Engine Symbol Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 To reset the oil monitoring system to 100% after each oil change (approximately 10,000 miles [16,000 km] or 12 months) perform the following. 1. Press the SETUP control to display "OIL LIFE= XXX% HOLD RESET=NEW". 2. Press and hold the RESET control for 2 seconds and release. Oil life is set to 100% and "OIL LIFE SET TO 100%" is displayed. 3. While "OIL LIFE SET TO 100%" is displayed, if a lower oil life start value is desired, press and release the RESET control to reduce the start value. Each press of the RESET control reduces the start value by 10 percent. NOTE: Oil life start value of 100% equals 10,000 miles [16,000 km] or 12 months. For example, setting oil life start value to 60% sets the oil life start value to 6,000 miles [9,600 km] and 219 days. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 7605 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the pin-type retainer, the 5 bolts and the RH splash shield. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the Engine Oil Pressure (EOP) switch electrical connector. 4. Remove the EOP switch. - To install, tighten to 15 Nm (133 lb-in). 5. To install, reverse the removal procedure. - Apply thread sealant with PTFE to the EOP switch threads. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 7608 Oil Pressure Sender: Service and Repair Exploded View - Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 7609 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 7610 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 7611 Oil Pressure Sender: Service and Repair Exploded View - Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Engine Lubrication Components - Exploded View Oil Filter Adapter, Oil Filter Element and Engine Oil Pressure (EOP) Switch (view 1 of 2) Oil Filter Adapter, Oil Filter and Engine Oil Pressure (EOP) Switch (view 2 of 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 7612 Oil Pan, Oil Pump Screen and Pickup Tube Oil Pump Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure (EOP) Switch > Page 7613 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Technical Service Bulletins > Customer Interest: > 08-23-12 > Nov > 08 > Temperature Display - Toggles From Fahrenheit To Celsius Outside Temperature Display: Customer Interest Temperature Display - Toggles From Fahrenheit To Celsius TSB 08-23-12 11/24/08 FRONT DISPLAY INTERFACE MODULE (FDIM) - OUTSIDE TEMPERATURE DISPLAY TOGGLES BETWEEN FAHRENHEIT/CELSIUS FORD: 2008-2009 Escape Hybrid, Escape MERCURY: 2008-2009 Mariner Hybrid, Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles may exhibit an outside temperature display in the FDIM that toggles between Fahrenheit and Celsius. ACTION Reprogram the Instrument Cluster module to the latest calibration using IDS release 57.9 and higher with patch 13 or 58.2 and higher. This new calibration is not included in the VCM 2008.11 DVD. Calibration and IDS patch files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 082312A 2008-2009 Escape, 0.3 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Reprogram The Instrument Cluster, Authorization Decal Not Required.(Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-23-12 > Nov > 08 > Temperature Display Toggles From Fahrenheit To Celsius Outside Temperature Display: All Technical Service Bulletins Temperature Display - Toggles From Fahrenheit To Celsius TSB 08-23-12 11/24/08 FRONT DISPLAY INTERFACE MODULE (FDIM) - OUTSIDE TEMPERATURE DISPLAY TOGGLES BETWEEN FAHRENHEIT/CELSIUS FORD: 2008-2009 Escape Hybrid, Escape MERCURY: 2008-2009 Mariner Hybrid, Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles may exhibit an outside temperature display in the FDIM that toggles between Fahrenheit and Celsius. ACTION Reprogram the Instrument Cluster module to the latest calibration using IDS release 57.9 and higher with patch 13 or 58.2 and higher. This new calibration is not included in the VCM 2008.11 DVD. Calibration and IDS patch files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 082312A 2008-2009 Escape, 0.3 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Reprogram The Instrument Cluster, Authorization Decal Not Required.(Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Technical Service Bulletins > All Other Service Bulletins for Outside Temperature Display: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel Front Steering Knuckle: All Technical Service Bulletins ABS/TCS - Clicking Noise From Left Front Wheel TSB 09-5-5 03/23/09 LEFT FRONT ABS SENSOR CONTACTING TONE RING - VEHICLES BUILT 10/21/2008-10/31/2008 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built from 10/21/2008 to 10/31/2008 may exhibit a clicking or rubbing noise from the left front wheel speed sensor and/or exhibit ABS warning light activation. The left front wheel knuckle may have been machined incorrectly allowing the wheel speed sensor to contact the tone ring. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Measure the air gap between the left front wheel speed sensor and tone ring with a feeler gage. 2. If 0.02" (0.50 mm) or more - this procedure does not apply. Continue with normal diagnostics. 3. If less than 0.02" (0.5 mm) or evidence of contact - replace the left front wheel knuckle per Workshop Manual (WSM), Section 204-01 and the left front Wheel Speed Sensor per WSM, Section 206-09. Parts Block 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 090505A 2009 Escape Hybrid, 1.3 Hrs. Mariner Hybrid: Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Be Claimed With Operations B And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505A 2009 Escape, Mariner: 1.2 Hrs. Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Technical Service Bulletins > All Other Service Bulletins for Outside Temperature Display: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel > Page 7632 Be Claimed With Operations B And/Or C (Do Not Use With 2001 B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505B 2009 Escape, Mariner, 0.6 Hr. Escape Hybrid, Mariner Hybrid: Check Caster, Camber And Toe In Can Be Claimed With Operation A And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505C 2009 Escape, Mariner, 0.2 Hr. Escape Hybrid, Mariner Hybrid: Correct Toe-In Can Be Claimed With Operation A And B (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 3K186 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Technical Service Bulletins > All Other Service Bulletins for Outside Temperature Display: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel > Page 7638 Be Claimed With Operations B And/Or C (Do Not Use With 2001 B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505B 2009 Escape, Mariner, 0.6 Hr. Escape Hybrid, Mariner Hybrid: Check Caster, Camber And Toe In Can Be Claimed With Operation A And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505C 2009 Escape, Mariner, 0.2 Hr. Escape Hybrid, Mariner Hybrid: Correct Toe-In Can Be Claimed With Operation A And B (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 3K186 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7645 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7646 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Remove the parking brake release handle bolt. - To install, tighten to 10 Nm (89 lb-in). 2. Disconnect the warning indicator switch electrical connector. 3. Remove the bolt and warning indicator switch. - To install, tighten bolt to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-23-12 > Nov > 08 > Temperature Display - Toggles From Fahrenheit To Celsius Instrument Panel Control Module: Customer Interest Temperature Display - Toggles From Fahrenheit To Celsius TSB 08-23-12 11/24/08 FRONT DISPLAY INTERFACE MODULE (FDIM) - OUTSIDE TEMPERATURE DISPLAY TOGGLES BETWEEN FAHRENHEIT/CELSIUS FORD: 2008-2009 Escape Hybrid, Escape MERCURY: 2008-2009 Mariner Hybrid, Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles may exhibit an outside temperature display in the FDIM that toggles between Fahrenheit and Celsius. ACTION Reprogram the Instrument Cluster module to the latest calibration using IDS release 57.9 and higher with patch 13 or 58.2 and higher. This new calibration is not included in the VCM 2008.11 DVD. Calibration and IDS patch files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 082312A 2008-2009 Escape, 0.3 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Reprogram The Instrument Cluster, Authorization Decal Not Required.(Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-23-12 > Nov > 08 > Temperature Display - Toggles From Fahrenheit To Celsius Instrument Panel Control Module: All Technical Service Bulletins Temperature Display - Toggles From Fahrenheit To Celsius TSB 08-23-12 11/24/08 FRONT DISPLAY INTERFACE MODULE (FDIM) - OUTSIDE TEMPERATURE DISPLAY TOGGLES BETWEEN FAHRENHEIT/CELSIUS FORD: 2008-2009 Escape Hybrid, Escape MERCURY: 2008-2009 Mariner Hybrid, Mariner ISSUE Some 2008-2009 Escape and Mariner vehicles may exhibit an outside temperature display in the FDIM that toggles between Fahrenheit and Celsius. ACTION Reprogram the Instrument Cluster module to the latest calibration using IDS release 57.9 and higher with patch 13 or 58.2 and higher. This new calibration is not included in the VCM 2008.11 DVD. Calibration and IDS patch files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions 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 082312A 2008-2009 Escape, 0.3 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Reprogram The Instrument Cluster, Authorization Decal Not Required.(Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel Wheel Speed Sensor: All Technical Service Bulletins ABS/TCS - Clicking Noise From Left Front Wheel TSB 09-5-5 03/23/09 LEFT FRONT ABS SENSOR CONTACTING TONE RING - VEHICLES BUILT 10/21/2008-10/31/2008 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built from 10/21/2008 to 10/31/2008 may exhibit a clicking or rubbing noise from the left front wheel speed sensor and/or exhibit ABS warning light activation. The left front wheel knuckle may have been machined incorrectly allowing the wheel speed sensor to contact the tone ring. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Measure the air gap between the left front wheel speed sensor and tone ring with a feeler gage. 2. If 0.02" (0.50 mm) or more - this procedure does not apply. Continue with normal diagnostics. 3. If less than 0.02" (0.5 mm) or evidence of contact - replace the left front wheel knuckle per Workshop Manual (WSM), Section 204-01 and the left front Wheel Speed Sensor per WSM, Section 206-09. Parts Block 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 090505A 2009 Escape Hybrid, 1.3 Hrs. Mariner Hybrid: Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Be Claimed With Operations B And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505A 2009 Escape, Mariner: 1.2 Hrs. Replace The Left Front Wheel Knuckle And Wheel Speed Sensor Includes Time To Measure Air Gap This Labor Operation Can Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel > Page 7666 Be Claimed With Operations B And/Or C (Do Not Use With 2001 B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505B 2009 Escape, Mariner, 0.6 Hr. Escape Hybrid, Mariner Hybrid: Check Caster, Camber And Toe In Can Be Claimed With Operation A And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505C 2009 Escape, Mariner, 0.2 Hr. Escape Hybrid, Mariner Hybrid: Correct Toe-In Can Be Claimed With Operation A And B (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 3K186 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09-5-5 > Mar > 09 > ABS/TCS - Clicking Noise From Left Front Wheel > Page 7672 Be Claimed With Operations B And/Or C (Do Not Use With 2001 B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505B 2009 Escape, Mariner, 0.6 Hr. Escape Hybrid, Mariner Hybrid: Check Caster, Camber And Toe In Can Be Claimed With Operation A And/Or C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090505C 2009 Escape, Mariner, 0.2 Hr. Escape Hybrid, Mariner Hybrid: Correct Toe-In Can Be Claimed With Operation A And B (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 3K186 42 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Service and Repair Seat Belt Reminder Buzzer: Service and Repair Belt-Minder(R) Deactivating/Activating Preparation 1. Apply the parking brake before deactivating/activating the Belt-Minder(R). 2. Place the gear selector lever in PARK (P) (automatic transaxle) or NEUTRAL (N) (manual transaxle). 3. Place the ignition switch in the OFF position. 4. Close all the vehicle doors. 5. Unbuckle the driver and passenger safety belts. Deactivating/Activating NOTE: The driver and front passenger Belt-Minder(R) are deactivated/activated independently. When deactivating/activating one seating position, do not buckle the other position. 1. Place the ignition switch in the RUN position. (Do not start the engine.) 2. Wait until the safety belt warning lamp turns off (approximately 1 minute). 3. NOTE: Steps 3 must be completed within 50 seconds after the safety belt warning indicator turns off. For seating position being disabled, at a moderate rate, buckle then unbuckle the safety belt 3 times, ending with the safety belt in the unbuckled state. - After this step, the air bar warning indicator illuminates for 3 seconds. 4. Within 7 seconds after the air bar warning indicator turns off, at a moderate rate, buckle then unbuckle the safety belt. - This disables the Belt-Minder(R) feature for that seating position, if it is currently enabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds. - This enables the Belt-Minder(R) feature for that seating position, if it is currently disabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by another flash sequence of 4 times per second for 3 seconds. 5. After confirmation, the deactivation/activation procedure is complete. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Service and Repair Seat Belt Reminder Lamp: Service and Repair Belt-Minder(R) Deactivating/Activating Preparation 1. Apply the parking brake before deactivating/activating the Belt-Minder(R). 2. Place the gear selector lever in PARK (P) (automatic transaxle) or NEUTRAL (N) (manual transaxle). 3. Place the ignition switch in the OFF position. 4. Close all the vehicle doors. 5. Unbuckle the driver and passenger safety belts. Deactivating/Activating NOTE: The driver and front passenger Belt-Minder(R) are deactivated/activated independently. When deactivating/activating one seating position, do not buckle the other position. 1. Place the ignition switch in the RUN position. (Do not start the engine.) 2. Wait until the safety belt warning lamp turns off (approximately 1 minute). 3. NOTE: Steps 3 must be completed within 50 seconds after the safety belt warning indicator turns off. For seating position being disabled, at a moderate rate, buckle then unbuckle the safety belt 3 times, ending with the safety belt in the unbuckled state. - After this step, the air bar warning indicator illuminates for 3 seconds. 4. Within 7 seconds after the air bar warning indicator turns off, at a moderate rate, buckle then unbuckle the safety belt. - This disables the Belt-Minder(R) feature for that seating position, if it is currently enabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds. - This enables the Belt-Minder(R) feature for that seating position, if it is currently disabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by another flash sequence of 4 times per second for 3 seconds. 5. After confirmation, the deactivation/activation procedure is complete. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair Instrument Panel Dimmer Switch Removal and Installation 1. Remove the Instrument Cluster (IC) finish panel. 2. NOTE: The instrument panel dimmer switch is removed by releasing the tabs and pulling from behind. Release the tabs and remove the instrument panel dimmer switch assembly. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 7686 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 7690 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Gauge Sender: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Fuel Tank Filler Pipe Assembly Fuel Tank and Fuel Pump (FP) module Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 7693 Fuel Tank Supports Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 7694 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 7695 Fuel Gauge Sender: Service and Repair Fuel Pump Module Fuel Pump Module Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have 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 serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the Fuel Pump (FP) module access cover. 4. NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material. Disconnect the FP module electrical connector. 5. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage. Disconnect the fuel tube-to-FP module quick connect coupling. 6. Disconnect the fuel tank filler pipe recirculation tube-to-FP module quick connect coupling. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 7696 7. NOTE: For initial fuel draining, it is required to remove the fuel through the fuel tank filler pipe recirculation tube port on the FP module. Connect the Fuel Storage Tanker to the fuel tank filler pipe recirculation tube port on the FP module and remove approximately one-fourth of the fuel (from a completely full tank), lowering the fuel level below the FP module mounting flange. 8. NOTICE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP module when removing the lock ring. NOTE: When installing the FP module, install a new O-ring seal. Install the Fuel Tank Sender Unit Wrench and remove the FP module lock ring. 9. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm. NOTE: Some residual fuel may remain in the FP module. Carefully drain into a suitable container. Completely remove the FP module from the fuel tank. 10. NOTE: Inspect the surfaces of the FP module flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded. NOTE: To install, apply clean engine oil to the O-ring seal. Remove and discard the FP module O-ring seal. 11. NOTE: Make sure to install a new FP module O-ring seal and lock ring. To install, reverse the removal procedure. Make sure the alignment arrows on the FP module and the fuel tank meet before tightening the FP module lock ring. - Tighten the FP lock ring until it meets the stop tabs on the fuel tank. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7700 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7701 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Remove the parking brake release handle bolt. - To install, tighten to 10 Nm (89 lb-in). 2. Disconnect the warning indicator switch electrical connector. 3. Remove the bolt and warning indicator switch. - To install, tighten bolt to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Testing and Inspection/Programming and Relearning. NOTE: The Tire Pressure Monitoring System (TPMS) Training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. NOTE: Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place at the valve stem. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall at the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall at the valve stem and press and release the test button to train the RF tire pressure sensor. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 7707 8. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 7708 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" when a vehicle is stationary to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall at the tire valve stem. 3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. This feedback may not always be present, do not rely on it to reflect the most recent pressure data. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. If the sensor still does not respond, attempt to activate the same sensor again using the customer activation tool (if available). If the sensor still fails to train, attempt to train the sensor with the vehicle doors open. Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor. Activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 7713 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 7714 Ambient Light Sensor: Service and Repair Light Sensor Removal and Installation 1. Remove the sensor from the instrument panel. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 7722 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 7723 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 7724 Backup Lamp Switch: Service and Repair Reversing Lamp Switch Removal and Installation 1. Disconnect the reversing lamp switch electrical connector. 2. Remove the reversing lamp switch. - To install, tighten to 24 Nm (18 lb-ft). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7729 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7730 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7731 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7732 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7733 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7734 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7735 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7736 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7737 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7738 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7739 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7740 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7741 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7742 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7743 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7744 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7745 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7746 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7747 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7748 Brake Lamp: Connector Views Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7749 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7750 Brake Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 90-1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7751 90-2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7752 90-3 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Special Tools Used With Diagnostics Stoplamps Principles Of Operation Stoplamps Principles of Operation NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). The Smart Junction Box (SJB) monitors the input from the stoplamp switch. When the brake pedal is applied, voltage is routed to the SJB and the high mounted stoplamp. The SJB then supplies voltage to the stoplamps. Field-Effect Transistor (FET) Protection Field-Effect Transistor (FET) is a type of transistor that when used with module software can be used to monitor and control current flow on module outputs. The FET protection strategy is used to prevent module damage in the event of excessive current flow. The SJB utilizes a FET protective circuit strategy for many of its outputs (for example, a headlamp output circuit). Output loads (current level) are monitored for excessive current (typically short circuits) and are shut down (turns off the voltage or ground provided by the module) when a fault event is detected. A continuous DTC is stored at the fault event and a cumulative counter is started. When the demand for the output is no longer present, the module resets the FET circuit protection to allow the circuit to function. The next time the driver requests a circuit to activate that has been shut down by a previous short (FET protection) and the circuit remains shorted, the FET protection shuts off the circuit again and the cumulative counter advances. When the excessive circuit load occurs often enough, the module shuts down the output until a repair procedure is carried out. Each FET protected circuit has 3 predefined levels of short circuit tolerance based on the harmful effect of each circuit fault on the FET and the ability of the FET to withstand it. A module lifetime level of fault events is established based upon the durability of the FET. If the total tolerance level is determined to be 600 fault events, the 3 predefined levels would be 200, 400 and 600 fault events. When each tolerance level is reached, the continuous DTC that was stored on the first failure cannot be cleared by a command to clear the continuous DTCs. The module does not allow this code to be cleared or the circuit restored to normal operation until a successful self-test proves that the fault has been repaired. After the self-test has successfully completed (no on-demand DTCs present), DTC B106E and the associated continuous DTC (the DTC related to the shorted circuit) automatically clears and the circuit function returns. When the first or second level is reached, the continuous DTC (associated with the short circuit) sets along with DTC B106E. These DTCs can be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7755 cleared using the module on-demand self-test, then the Clear DTC operation on the scan tool (if the on-demand test shows the fault corrected). The module never resets the fault event counter to zero and continues to advance the fault event counter as short circuit fault events occur. If the number of short circuit fault events reach the third level, then DTCs B106F and B1342 set along with the associated continuous DTC. This DTC cannot be cleared and the module must be replaced. The SJB FET protected output circuits for the stoplamp system are the LH rear stop/turn lamp and the RH rear stop/turn lamp output circuits. Inspection And Verification Stoplamps Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC). 5. NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: - Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus, No Power To The Scan Tool, to diagnose no power to the scan tool. 6. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus to diagnose no response from the PCM. 7. Carry out the network test. - If the scan tool responds with no communication for one or more modules, refer to Information Bus. - If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the SJB. 9. If the DTCs retrieved are related to the concern, refer to Diagnostic Trouble Code (DTC) Chart See: Testing and Inspection. For all other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart in Body Control Systems. See: Body and Frame/Body Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7756 Brake Lamp: Symptom Related Diagnostic Procedures Stoplamps Symptom Chart Symptom Chart Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7757 Brake Lamp: Pinpoint Tests Pinpoint Test I: All The Stoplamps Are Inoperative Stoplamps Pinpoint Tests Pinpoint Test I: All The Stoplamps Are Inoperative Refer to Wiring Diagram Set 90 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Turn Signal/Stop/Hazard Lamps for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The stoplamp switch is supplied voltage through circuit SBP02 (YE/RD) from the Smart Junction Box (SJB). When the brake pedal is applied, the stoplamp switch routes voltage back to the SJB and the high mounted stoplamp through circuit CCB08 (VT/WH). The SJB provides voltage to the rear lamps when it receives input from the stoplamp switch indicating that the brake pedal is applied. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Stoplamp switch - SJB PINPOINT TEST I: ALL THE STOPLAMPS ARE INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. ------------------------------------------------- I1 CHECK FOR VOLTAGE TO THE STOPLAMP SWITCH - Ignition OFF. - Disconnect: Stoplamp Switch C278. - Measure the voltage between the stoplamp switch C278-1, circuit SBP02 (YE/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to I2. No VERIFY the SJB fuse 2 (15A) is OK. If OK, GO to I3. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- I2 CHECK THE STOPLAMP SWITCH - Connect a fused jumper wire between the stoplamp switch C278-1, circuit SBP02 (YE/RD), harness side and the stoplamp switch C278-4, circuit CCB08 (VT/WH), harness side. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7758 - Are the stoplamps illuminated? Yes INSTALL a new stoplamp switch. REFER to Stoplamp Switch See: Brake Light Switch/Service and Repair. TEST the system for normal operation. No REPAIR circuit CCB08 (VT/WH) for an open. TEST the system for normal operation. ------------------------------------------------- I3 CHECK CIRCUIT SBP02 (YE/RD) FOR AN OPEN - Disconnect: SJB C2280d. - Measure the resistance between the stoplamp switch C278-1, circuit SBP02 (YE/RD), harness side and the SJB C2280d-13, circuit SBP02 (YE/RD), harness side. - Is the resistance less than 5 ohms? Yes GO to I4. No REPAIR SBP02 (YE/RD) for an open. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- I4 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------Pinpoint Test J: One Or More Stoplamps Are Inoperative Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7759 Stoplamps Pinpoint Tests Pinpoint Test J: One Or More Stoplamps Are Inoperative Refer to Wiring Diagram Set 90 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Turn Signal/Stop/Hazard Lamps for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation When the brake pedal is applied, the stoplamp switch routes voltage to the Smart Junction Box (SJB) and the high mounted stoplamp through circuit CCB08 (VT/WH). When the SJB detects the brake pedal is applied, the SJB provides voltage to the LH and RH rear stoplamps through circuits CLS18 (GY/BN) and CLS19 (VT/OG), respectively. Ground for the LH and RH rear stoplamps is provided through circuit GD149 (BK/GY). Ground for the high mounted stoplamp is provided through circuit GD183 (BK/WH). NOTE: SJB fuse 6 (20A) supplies voltage for both combination rear stop/turn lamps and both front turn lamps. B106E-B2047 This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - High mounted stoplamp - Bulb holder - SJB PINPOINT TEST J: ONE OR MORE STOPLAMPS ARE INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. ------------------------------------------------- J1 DETERMINE THE INOPERATIVE STOPLAMP - Ignition OFF. - Apply the brake pedal and observe the stoplamps. - Are all the stoplamps inoperative? Yes Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7760 Go To Pinpoint Test H. See: Headlamp/Testing and Inspection/Pinpoint Tests/Autolamps/Pinpoint Test H: The Autolamps Are On Continuously No For the high mounted stoplamp, GO to J2. If only one side (the LH or RH rear stoplamp) is inoperative, GO to J6. If both sides (LH and RH rear stoplamps) are inoperative, VERIFY the SJB fuse 6 (20A) is OK. If OK, GO to J4. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. After the repair: If no DTCs are present, TEST the system for normal operation. If DTC B106E is present, CLEAR the DTCs and REPEAT the self-test (required to enable the stoplamp output driver if DTC B106E is present). TEST the system for normal operation. If DTC B106F is present, INSTALL a new SJB. TEST the system for normal operation. ------------------------------------------------- J2 CHECK FOR VOLTAGE TO THE HIGH MOUNTED STOPLAMP - Disconnect: High Mounted Stoplamp C475. - While applying the brake pedal, measure the voltage between the high mounted stoplamp C475-1, circuit CCB08 (VT/WH), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to J3. No REPAIR CCB08 (VT/WH) for an open. TEST the system for normal operation. ------------------------------------------------- J3 CHECK FOR VOLTAGE TO THE HIGH MOUNTED STOPLAMP USING THE CONNECTOR GROUND - While applying the brake pedal, measure the voltage between the high mounted stoplamp C475-1, circuit CCB08 (VT/WH), harness side and the high mounted stoplamp C475-2, circuit GD183 (BK/WH), harness side. - Is the voltage greater than 10 volts? Yes INSTALL a new high mounted stoplamp. TEST the system for normal operation. No Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7761 REPAIR circuit GD183 (BK/WH) for an open. TEST the system for normal operation. ------------------------------------------------- J4 CHECK FOR VOLTAGE TO THE LH STOPLAMP - Disconnect: LH Rear Lamp C4035. - While applying the brake pedal, measure the voltage between the LH rear lamp C4035-3, circuit CLS18 (GY/BN), harness side and ground. - Is the voltage greater than 10 volts? Yes REPAIR circuit GD149 (BK/GY) for an open. TEST the system for normal operation. No GO to J5. ------------------------------------------------- J5 CHECK FOR VOLTAGE TO THE SJB - Disconnect: SJB C2280b. - While applying the brake pedal, measure the voltage between the SJB C2280b-40, circuit CCB08 (VT/WH), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to J11. No REPAIR circuit CCB08 (VT/WH) for an open. TEST the system for normal operation. ------------------------------------------------- J6 USE THE RECORDED DTCs FROM THE SJB SELF-TEST - Clear the DTCs and repeat the on-demand self-test. - Is DTC B2045 or DTC B2047 present? Yes GO to J7. No GO to J10. ------------------------------------------------- J7 CHECK FOR VOLTAGE TO THE BULB HOLDER - Disconnect: Inoperative Rear Lamp. - While applying the brake pedal, measure the voltage between the LH rear lamp C4035-3, circuit CLS18 (GY/BN), harness side and ground; or between the RH rear lamp C4032-3, circuit CLS19 (VT/OG), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7762 - Is the voltage greater than 10 volts? Yes GO to J8. No GO to J9. ------------------------------------------------- J8 CHECK FOR VOLTAGE TO THE INOPERATIVE STOPLAMP USING THE CONNECTOR GROUND - While applying the brake pedal, measure the voltage between the LH rear lamp C4035-3, circuit CLS18 (GY/BN), harness side and the LH rear lamp C4035-1, circuit GD149 (BK/GY), harness side; or between the RH rear lamp C4032-3, circuit CLS19 (VT/OG), harness side and the RH rear lamp C4032-1, circuit GD149 (BK/GY), harness side. - Is the voltage greater than 10 volts? Yes INSTALL a new bulb holder. CLEAR the DTCs. REPEAT the self-test. No REPAIR circuit GD149 (BK/GY) for an open. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- J9 CHECK CIRCUIT CLS18 (GY/BN) OR CIRCUIT CLS19 (VT/OG) FOR AN OPEN - Disconnect: SJB C2280d. - Measure the resistance between the LH rear lamp C4035-3, circuit CLS18 (GY/BN), harness side and the SJB C2280d-25, circuit CLS18 (GY/BN), harness side; or between the RH rear lamp C4032-3, circuit CLS19 (VT/OG), harness side and the SJB C2280d-26, circuit CLS19 (VT/OG), harness side. Is the resistance less than 5 ohms? Yes GO to J12. No REPAIR the circuit in question for an open. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- J10 CHECK THE BULB HOLDER FOR A SHORT TO GROUND Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7763 - Disconnect: Inoperative Rear Lamp. - Ignition ON. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the DTCs and repeat the self-test (required to enable the turn lamp output driver if DTC B106E is present). - While applying the brake pedal, measure the voltage between the LH rear lamp C4035-3, circuit CLS18 (GY/BN), harness side and ground; or between the RH rear lamp C4032-3, circuit CLS19 (VT/OG), harness side and ground. - Is the voltage greater than 10 volts? Yes INSTALL a new bulb holder. TEST the system for normal operation. No GO to J11. ------------------------------------------------- J11 CHECK THE SJB STOPLAMP OUTPUT CIRCUIT FOR A SHORT TO GROUND - Ignition OFF. - Disconnect: SJB C2280d. - Disconnect: LH and RH Trailer Tow Stop/Turn Relays. - Measure the resistance between the SJB C2280d-25, circuit CLS18 (GY/BN), harness side and ground; or between the SJB C2280d-26, circuit CLS19 (VT/OG), harness side and ground. - Is the resistance greater than 10,000 ohms? Yes GO to J12. No REPAIR circuit CLS18 (GY/BN) (LH rear stoplamp) or circuit CLS19 (VT/OG) (RH rear stoplamp) for a short to ground. After the repair: If no DTCs are present, TEST the system for normal operation. If DTC B106E is present, CLEAR the DTCs and REPEAT the self-test (required to enable the turn lamp output driver if DTC B106E is present). TEST the system for normal operation. If DTC B106F is present, INSTALL a new SJB. TEST the system for normal operation. ------------------------------------------------- J12 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7764 - Is the concern still present? Yes INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------Pinpoint Test K: The Stoplamps Are On Continuously Stoplamps Pinpoint Tests Pinpoint Test K: The Stoplamps Are On Continuously Refer to Wiring Diagram Set 90 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Turn Signal/Stop/Hazard Lamps for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number When the brake pedal is applied, the stoplamp switch routes voltage to the Smart Junction Box (SJB), the high mounted stoplamp, the PCM and the speed control actuator through circuit CCB08 (VT/WH). When the SJB detects the brake pedal is applied, the SJB provides voltage to the LH and RH rear stoplamps through circuits CLS18 (GY/BN) and CLS19 (VT/OG), respectively. If equipped with trailer tow, voltage is also supplied to the respective trailer tow stop/turn relay. - DTC B1485 (Brake Pedal Input Short to Battery) - an on-demand DTC that sets when the SJB detects a short to voltage from the stoplamp switch input circuit. - DTC B2045 (Left Rear Stop Lamp Circuit Open) - an on-demand DTC that sets when the SJB detects a short to voltage from the LH rear stop/turn lamp voltage supply circuit. - DTC B2047 (Right Rear Stoplamp Circuit Open) - an on-demand DTC that sets when the SJB detects a short to voltage from the RH rear stop/turn lamp voltage supply circuit. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Stoplamp switch - PCM - SJB PINPOINT TEST K: THE STOPLAMPS ARE ON CONTINUOUSLY ------------------------------------------------- K1 DETERMINE IF ALL THE STOPLAMPS ARE ILLUMINATED - Ignition OFF. - Observe the stoplamps with the brake pedal released. - Are all of the stoplamps illuminated? Yes GO to K3. No GO to K2. ------------------------------------------------- K2 CHECK THE STOPLAMPS VOLTAGE SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE - Disconnect: SJB C2280d. - Do the stoplamps continue to illuminate? Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7765 Yes If the LH rear lamp continues to illuminate, REPAIR circuit CLS18 (GY/BN) for a short to voltage. CLEAR the DTCs. REPEAT the self-test. If the RH rear lamp continues to illuminate, REPAIR circuit CLS19 (VT/OG) for a short to voltage. CLEAR the DTCs. REPEAT the self-test. No GO to K7. ------------------------------------------------- K3 CHECK THE STOPLAMP SWITCH - Disconnect: Stoplamp Switch C278. - Do the stoplamps continue to illuminate? Yes GO to K4 . No INSTALL a new stoplamp switch. REFER to Stoplamp Switch See: Brake Light Switch/Service and Repair. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- K4 CHECK THE PCM - Disconnect: PCM C175b. - Do the stoplamps continue to illuminate? Yes GO to K5. No GO to K6. ------------------------------------------------- K5 CHECK CIRCUIT CCB08 (VT/WH) FOR A SHORT TO VOLTAGE - Disconnect: SJB C2280b. Does the high mounted stoplamp continue to illuminate? Yes REPAIR circuit CLS19 (VT/OG) for a short to voltage. CLEAR the DTCs. REPEAT the self-test. No GO to K7. ------------------------------------------------- K6 CHECK FOR CORRECT PCM OPERATION - Disconnect all the PCM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the PCM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7766 INSTALL a new PCM. CLEAR the DTCs. REPEAT the self-test. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- K7 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. Is the concern still present? Yes INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 09-15-1 > Aug > 09 > ABS/TCS - Traction Control Lamp ON/DTC C1440 Set Brake Light Switch: Customer Interest ABS/TCS - Traction Control Lamp ON/DTC C1440 Set TSB 09-15-1 08/10/09 TRACTION CONTROL LIGHT WITH DTC C1440 - BUILT 6/1/2009-6/10/2009 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built on or between 6/1/2009 to 6/10/2009, may exhibit the traction control light on with DTC code C1440. If the vehicle is operated for an extended period following the illumination of the traction control light, a slight brake drag condition may be observed. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE If the vehicle was built on or between 6/01/2009 to 6/10/2009, and both the traction control light and DTC C1440 are present, then replace the brake pedal switch. If only one is present, and not the other, then proceed with normal diagnostics. Refer to Workshop Manual (WSM), Section 417-01 for brake pedal switch replacement. NOTE DO NOT PRESS OR PULL ON BRAKE PEDAL WHEN INSTALLING OR REMOVING THE STOPLAMP SWITCH OTHERWISE MISADJUSTMENT OR DAMAGE TO THE STOPLAMP SWITCH CAN OCCUR. Parts Block 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 091501A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Replace The Stoplamp Switch. Includes Time To Check For DTCs (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 13480 12 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09-15-1 > Aug > 09 > ABS/TCS - Traction Control Lamp ON/DTC C1440 Set Brake Light Switch: All Technical Service Bulletins ABS/TCS - Traction Control Lamp ON/DTC C1440 Set TSB 09-15-1 08/10/09 TRACTION CONTROL LIGHT WITH DTC C1440 - BUILT 6/1/2009-6/10/2009 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built on or between 6/1/2009 to 6/10/2009, may exhibit the traction control light on with DTC code C1440. If the vehicle is operated for an extended period following the illumination of the traction control light, a slight brake drag condition may be observed. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE If the vehicle was built on or between 6/01/2009 to 6/10/2009, and both the traction control light and DTC C1440 are present, then replace the brake pedal switch. If only one is present, and not the other, then proceed with normal diagnostics. Refer to Workshop Manual (WSM), Section 417-01 for brake pedal switch replacement. NOTE DO NOT PRESS OR PULL ON BRAKE PEDAL WHEN INSTALLING OR REMOVING THE STOPLAMP SWITCH OTHERWISE MISADJUSTMENT OR DAMAGE TO THE STOPLAMP SWITCH CAN OCCUR. Parts Block 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 091501A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Replace The Stoplamp Switch. Includes Time To Check For DTCs (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 13480 12 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 7780 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 7781 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 7782 Brake Light Switch: Service and Repair Stoplamp Switch Removal and Installation NOTICE: Do not press or pull on brake pedal when installing or removing the stoplamp switch otherwise misadjustment or damage to the stoplamp switch could occur. 1. Disconnect the stoplamp switch electrical connector. 2. Rotate the stoplamp switch clockwise approximately one-eighth turn and remove the stoplamp switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams Cargo Lamp: Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp Switch > Component Information > Service and Repair Console Lamp Switch: Service and Repair Ambient Lighting Switch Removal and Installation 1. Remove the floor console finish panel. - Disconnect the electrical connector. 2. Squeeze the retaining tabs and remove the ambient lighting switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Locations > Page 7796 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7801 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7802 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7803 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7804 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7805 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7806 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7807 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7808 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7809 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7810 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7811 Daytime Running 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7812 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7813 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7814 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7815 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7816 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7817 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7818 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7819 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7820 Daytime Running Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 97-1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7821 97-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Daytime Running Lamp: Initial Inspection and Diagnostic Overview Principles Of Operation Daytime Running Lamps (DRL) Principles of Operation NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). NOTE: When installing a new SJB, it must be configured for this feature, if originally equipped. Refer to Information Bus. The SJB controls the Daytime Running Lamps (DRL) by using various inputs to determine whether or not the DRL should be illuminated. These inputs include: - Ignition switch position - Headlamp switch position - Headlamps on or off - Transmission gear selection (automatic transmission) - Parking brake applied or released (manual transmission) When the DRL is active, the SJB provides a pulse-width modulated voltage to the low beam headlamps. This illuminates the headlamps at a reduced intensity. The SJB can be configured to turn the DRL on for this vehicle. Refer to Information Bus for additional information on this programmable parameter. Special Tools Used With Diagnostics Daytime Running Lamps (DRL) Inspection And Verification Daytime Running Lamps (DRL) Inspection and Verification 1. Verify the customer concern. 2. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 3. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC). 4. NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: - Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus, No Power To The Scan Tool, to diagnose no power to the scan tool. 5. If the scan tool does not communicate with the vehicle: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7824 - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus to diagnose no response from the PCM. 6. Carry out the network test. - If the scan tool responds with no communication for one or more modules, refer to Information Bus. - If the network test passes, retrieve and record the continuous memory DTCs. 7. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM, the Smart Junction Box (SJB), and the Instrument Cluster (IC). 8. If the DTCs retrieved are related to the concern, refer to Computers and Control Systems Information or Body Control Systems. 9. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7825 Daytime Running Lamp: Symptom Related Diagnostic Procedures Daytime Running Lamps (DRL) Symptom Chart Symptom Chart Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7826 Daytime Running Lamp: Pinpoint Tests Daytime Running Lamps (DRL) Pinpoint Tests Pinpoint Test AC: The Daytime Running Lamps (DRL) Are Inoperative Normal Operation When the ignition switch is in the RUN position, the headlamps are not on (from the autolamp system or manual control from the headlamp switch), the transaxle is not in PARK (P) (automatic transaxle) or the parking brake is not applied (manual transaxle), the Smart Junction Box (SJB) provides a pulse-width modulated voltage to the low beam headlamps. This illuminates the headlamps at a reduced intensity. This pinpoint test is intended to diagnose the following: - Exterior lighting system input/output - Ignition switch input - Transaxle gear input (automatic transaxle) - Parking brake switch input (manual transaxle) - SJB PINPOINT TEST AC: THE DRL ARE INOPERATIVE ------------------------------------------------- AC1 VERIFY THE DRL OPERATION - Ignition ON. - Place the headlamp switch in the OFF position. - If equipped with an automatic transaxle, place the gear selector lever in any gear other than PARK (P). - If equipped with a manual transaxle, release the parking brake. Do the DRL illuminate? Yes The system is operating correctly. INFORM the customer of the conditions required for the DRL to operate correctly. No GO to AC2. ------------------------------------------------- AC2 CHECK FOR RECORDED SJB DTCs - Review the recorded results from the SJB self-test. - Are any DTCs present? Yes REFER to Body Control Systems. No GO to AC3. ------------------------------------------------- AC3 CHECK THE OPERATION OF THE HEADLAMPS - Place the headlamp switch in each of its positions (including autolamps if equipped) and observe the headlamps. - Do the headlamps and autolamps (if equipped) operate correctly? Yes GO to AC4. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7827 No REFER to Headlamps See: Headlamp/Testing and Inspection or Autolamps See: Headlamp/Testing and Inspection. ------------------------------------------------- AC4 CHECK THE IGNITION SWITCH INPUT - Place the headlamp switch in the OFF position. - Enter the following diagnostic mode on the scan tool: DataLogger. - Monitor the SJB ignition switch PID (IGN_A_ECU, IGN_O_ECU, IGN_R_ECU) while cycling the ignition switch through all positions (states). - Does the PID agree with the ignition switch positions? Yes For vehicles with an automatic transaxle, GO to AC5. For vehicles with a manual transaxle, GO to AC6. No REFER to Steering Column. See: Steering and Suspension/Steering/Steering Column/Testing and Inspection ------------------------------------------------- AC5 CHECK THE TRANSAXLE GEAR INPUT - Ignition ON. - Enter the following diagnostic mode on the scan tool: DataLogger. - Monitor the PCM transmission gear status PID (TR) while placing the gear selector lever through all its positions. - Does the PID agree with the gear selection? Yes INSTALL a new SJB. TEST the system for normal operation. No Refer to Transmission Control Systems. See: Powertrain Management/Transmission Control Systems/Testing and Inspection ------------------------------------------------- AC6 CHECK THE BRAKE WARNING INDICATOR OPERATION - Ignition ON. - Apply and release the parking brake while observing the brake warning indicator. - Does the brake warning indicator operate correctly? Yes GO to AC7 No REFER to Instrument Panel, Gauges and Warning Indicators. ------------------------------------------------- AC7 CHECK THE SJB FOR DRL CONFIGURATION - Enter the following diagnostic mode on the scan tool: SJB Module Programming. - Check the SJB configuration and make sure the DRL feature is enabled. - Is the SJB DRL configuration enabled? Yes INSTALL a new SJB. TEST the system for normal operation. No Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7828 ENABLE the DRL configuration. TEST the system for normal operation. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Page 7829 Daytime Running Lamp: Adjustments Autolamps Time Delay Adjustment NOTE: The time delay can be programmed through the instrument cluster message center using the message center buttons (if equipped) or using the following steps. NOTE: Steps 2 through 5 must be carried out within a 10-second period. 1. Start with the ignition switch off and the headlamp switch in the AUTOLAMPS ON position. 2. Place the headlamp switch in the OFF position. 3. Place the ignition switch in the RUN position. 4. Place the ignition switch in the OFF position. 5. Place the headlamp switch in the AUTOLAMPS ON position. The exterior lamps turn on at this point. 6. Wait the desired amount of time and place the headlamp switch in the OFF position (maximum of 3 minutes). The exterior lamps turn off and the autolamp time delay is now set. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair Instrument Panel Dimmer Switch Removal and Installation 1. Remove the Instrument Cluster (IC) finish panel. 2. NOTE: The instrument panel dimmer switch is removed by releasing the tabs and pulling from behind. Release the tabs and remove the instrument panel dimmer switch assembly. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair Dome Lamp: Service and Repair Interior Lamp Removal and Installation 1. Open the overhead console storage door to access the screws. - Remove the 2 screws. 2. Pull the overhead console down and remove the console from the headliner retainer. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 7839 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair Fog Lamp Bulb Mariner Escape Removal and Installation WARNING: The bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. NOTICE: 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. NOTE: Make sure the headlamp switch and the ignition switch are in the OFF position. All vehicles Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Page 7844 1. With the vehicle in NEUTRAL, position it on a hoist. Escape 2. Remove the 4 fender splash shield bolts. - To install, tighten to 5 Nm (44 lb-in). 3. Remove the 4 fender splash shield pin-type retainers. - Position the fender splash shield aside. 4. Disconnect the fog lamp electrical connector. 5. Squeeze both tabs on the fog lamp bulb simultaneously and remove it from the fog lamp. Mariner 6. Rotate the fog lamp bulb approximately one-eighth turn counterclockwise and remove. - Disconnect the electrical connector. All vehicles 7. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Lamps: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7849 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7850 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7851 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7852 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7853 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7854 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7855 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7856 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7857 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7858 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7859 Hazard Warning 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7860 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7861 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7862 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7863 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7864 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7865 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7866 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7867 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7868 Hazard Warning Lamps: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 90-1 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7869 90-2 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7870 90-3 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair Headlamp Bulb Removal and Installation WARNING: The bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. NOTICE: 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. NOTE: Make sure the headlamp switch and the ignition switch are in the OFF position. 1. Disconnect the headlamp bulb electrical connector. 2. Rotate the headlamp bulb one-eighth turn counterclockwise and remove the headlamp bulb. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 7878 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 7881 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 7882 Headlamp Dimmer Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 7883 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 7884 Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation 1. Remove the steering column opening trim. 2. Remove the 3 lower steering column shroud screws. 3. Remove the upper and lower steering column shrouds. 4. Remove the 2 multifunction switch screws. 5. Disconnect the multifunction switch electrical connector and remove the switch. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7888 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7889 Headlamp Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7890 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7891 Headlamp Switch: Service and Repair Headlamp Switch Removal and Installation 1. Remove the instrument panel side finish panel. 2. NOTE: The headlamp switch is removed by pushing from behind. Release the tabs and remove the headlamp switch. - Disconnect the electrical connectors. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Specifications Horn: Specifications Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions Horn: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7897 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7898 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7899 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7900 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7901 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7902 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7903 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7904 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7905 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7906 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7907 Horn: 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7908 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7909 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7910 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7911 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7912 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7913 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7914 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7915 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7916 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7917 Horn: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 44-1 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and Instructions > Page 7918 Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Page 7919 Horn: Description and Operation Horn NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). There are 2 separate conditions that can cause the horn to sound. The horn sounds when the driver presses the horn switch or when the panic button is pressed on the Integrated Keyhead Transmitter (IKT). The horn system uses the SJB to provide voltage to the horn, while the horn switch or the SJB can provide the ground to engage the horn relay. The horn switch is integrated into the air bag. For the removal and installation of the air bag, refer to Air Bag Systems. Horn Location The horn is mounted on the LH side of the core support behind the bumper cover under the headlamp. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Horn: Initial Inspection and Diagnostic Overview Special Tools Used With Diagnostics Horn Inspection and Verification Horn Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart Principles of Operation Horn Principles of Operation NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). The SJB supplies the control voltage to the horn relay (part of the SJB). When the horn switch (part of the steering wheel) is pressed, ground is supplied to the horn relay sending voltage to the horn, enabling the horn to sound. The SJB provides a momentary on then off ground when the panic button is pressed on the Integrated Keyhead Transmitter (IKT). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7922 Horn: Symptom Related Diagnostic Procedures Horn Symptom Chart Symptom Chart Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7923 Horn: Pinpoint Tests Pinpoint Test A: The Horn Is Inoperative Horn Pinpoint Tests Pinpoint Test A: The Horn Is Inoperative Refer to Wiring Diagram Set 44 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Horn/Cigar Lighter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Smart Junction Box (SJB) supplies the voltage to the horn relay (part of the SJB). When the horn switch (part of the steering wheel) is pressed, the switch closes and ground is applied from the steering wheel switch harness through the clockspring to the horn relay through circuit CRH03 (BN). The horn relay is then energized, applying voltage to the horn through circuit SRH01 (YE/RD), enabling the horn to sound. Ground for the horn is supplied through circuit GD120 (BK/GN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Steering wheel switch harness - Horn - Clockspring - Horn switch (part of the steering wheel) - SJB PINPOINT TEST A: THE HORN IS INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to battery. ------------------------------------------------- A1 CHECK THE SJB OUTPUT - Ignition ON. - Enter the following diagnostic mode on the scan tool: SJB DataLogger. - Select the SJB PID (HORN), and Command the horn on and then off. - Does the horn sound when commanded on? Yes GO to A2. No GO to A7. ------------------------------------------------- A2 CHECK CIRCUIT CRH03 (BN) FOR VOLTAGE - Depower the Supplemental Restraint System (SRS). Refer to Air Bag Systems. - Disconnect: Clockspring C218. - Connect: Negative Battery Cable. - Measure the voltage between the clockspring C218-1, circuit CRH03 (BN), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7924 - Is the voltage greater than 10 volts? Yes GO to A4. No GO to A3. ------------------------------------------------- A3 CHECK CIRCUIT CRH03 (BN) FOR AN OPEN - Disconnect: SJB C2280b. - Measure the resistance between SJB C2280b-41 , harness side and the clockspring C218-1, circuit CRH03 (BN), harness side. - Is the resistance less than 5 ohms? Yes GO to A10. No REPAIR the circuit. REPOWER the SRS. REFER to Air Bag Systems. TEST the system for normal operation. ------------------------------------------------- A4 CHECK THE CLOCKSPRING FOR AN OPEN - Remove the driver air bag module. - Disconnect: Upper Clockspring Connector. - Measure the resistance between the clockspring C218 pin 1, component side and the upper clockspring connector pin 1, component side. - Is the resistance less than 5 ohms? Yes GO to A5. No Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7925 INSTALL a new clockspring. TEST the system for normal operation. ------------------------------------------------- A5 CHECK CIRCUIT GD112 (BK/GN) FOR AN OPEN - Measure the resistance between the clockspring C218-7, circuit GD112 (BK/GN), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to A6. No REPAIR the circuit. INSTALL the driver air bag. TEST the system for normal operation. ------------------------------------------------- A6 CHECK THE STEERING WHEEL SWITCH HARNESS FOR DAMAGE OR OPENS - Inspect the steering wheel switch harness for damage or opens. - Is the steering wheel switch harness OK? Yes INSTALL a new steering wheel. TEST the system for normal operation. No REPAIR or INSTALL a new steering wheel switch harness. INSTALL the driver air bag module. TEST the system for normal operation. ------------------------------------------------- A7 CHECK CIRCUIT GD120 (BK/GN) FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Disconnect: Horn C1101. - Measure the resistance between the horn C1101-1, circuit GD120 (BK/GN), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to A8. No REPAIR the circuit. TEST the system for normal operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7926 ------------------------------------------------- A8 CHECK CIRCUIT SRH01 (YE/RD) FOR VOLTAGE - Connect: Negative Battery Cable. - Measure the voltage between the horn C1101-2, circuit SRH01 (YE/RD), harness side, and the horn C1101-1, circuit GD120 (BK/GN), harness side, while pressing the horn switch. - Is the voltage greater than 10 volts? Yes INSTALL a new horn. REFER to Horn See: Service and Repair. TEST the system for normal operation. No VERIFY the SJB fuse 24 (20A) is OK. If OK, GO to A9. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- A9 CHECK CIRCUIT SRH01 (YE/RD) FOR AN OPEN - Disconnect: SJB C2280e. - Measure the resistance between the SJB C2280e-5, circuit SRH01 (YE/RD), harness side, and the horn C1101-2, circuit SRH01 (YE/RD), harness side. - Is the resistance less than 5 ohms? Yes GO to A10. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- A10 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7927 ------------------------------------------------Pinpoint Test B: The Horn Is Always On Horn Pinpoint Tests Pinpoint Test B: The Horn Is Always On Refer to Wiring Diagram Set 44 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Horn/Cigar Lighter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Smart Junction Box (SJB) supplies the voltage to the horn relay (part of the SJB). When the horn switch (part of the steering wheel) is pressed, the switch closes and ground is applied from the steering wheel switch harness through the clockspring to the horn relay through circuit CRH03 (BN). The horn relay is then energized, applying voltage to the horn through circuit SRH01 (YE/RD), enabling the horn to sound. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Steering wheel switch harness - Clockspring - Horn switch (part of the steering wheel) - SJB PINPOINT TEST B: THE HORN IS ALWAYS ON NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. ------------------------------------------------- B1 CHECK CIRCUIT SRH01 (YE/RD) FOR A SHORT TO VOLTAGE - Ignition OFF. - Disconnect: SJB C2280e. - Does the horn continue to sound? Yes REPAIR the circuit. TEST the system for normal operation. No GO to B2. ------------------------------------------------- B2 CHECK THE HORN SWITCH INPUT - Disconnect: SJB C2280b. - Connect: SJB C2280e. - Does the horn continue to sound? Yes GO to B6. No GO to B3. ------------------------------------------------- B3 CHECK CIRCUIT CRH03 (BN) FOR A SHORT TO GROUND - Depower the Supplemental Restraint System (SRS). Refer to Air Bag Systems. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7928 - Disconnect: Clockspring C218. - Measure the resistance between the clockspring C218-1, circuit CRH03 (BN), harness side and ground. - Is the resistance greater than 10,000 ohms? Yes GO to B4. No REPAIR the circuit. REPOWER the SRS. REFER to Air Bag Systems. TEST the system for normal operation. ------------------------------------------------- B4 CHECK THE CLOCKSPRING FOR A SHORT TO GROUND - Remove the driver air bag module. - Connect: Clockspring C218. - Measure the resistance between the SJB C2280b-41, circuit CRH03 (BN), harness side and ground. - Is the resistance greater than 10,000 ohms? Yes GO to B5. No INSTALL a new clockspring. INSTALL the driver air bag module. TEST the system for normal operation. ------------------------------------------------- B5 CHECK THE STEERING WHEEL SWITCH HARNESS FOR DAMAGE OR SHORTS - Inspect the steering wheel switch harness for damage or shorts. - Is the steering wheel switch harness OK? Yes INSTALL a new steering wheel. TEST the system for normal operation. No REPAIR or INSTALL a new steering wheel switch harness. INSTALL the driver air bag module. TEST the system for normal operation. ------------------------------------------------- B6 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7929 - corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. Is the concern still present? Yes INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Component Information > Testing and Inspection > Page 7930 Horn: Service and Repair Horn Removal and Installation 1. Remove the front bumper cover. 2. Disconnect the electrical connector. 3. Remove the bolt and the horn. - To install, tighten to 9 Nm (80 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 7934 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 7935 Interior Lighting Module: Service and Repair Ambient Lighting Module Removal and Installation 1. Remove the center console finish panel. 2. Remove the 2 screws and the ambient lighting module. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7940 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7941 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7942 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7943 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7944 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7945 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7946 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7947 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7948 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7949 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7950 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7951 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7952 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7953 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7954 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7955 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7956 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7957 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7958 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7959 License Plate Lamp: Connector Views Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7960 License Plate Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-1 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7961 Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7966 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7967 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7968 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7969 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7970 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7971 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7972 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7973 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7974 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7975 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7976 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7977 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7978 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7979 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7980 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7981 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7982 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7983 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7984 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7985 Marker Lamp: Connector Views Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7986 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7987 Marker Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-1 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7988 Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 7989 Marker Lamp: Service and Repair Side Lamp/Front Turn Signal Lamp Bulb Side Lamp (Escape) Front Turn Signal Lamp Bulb NOTE: Escape shown, Mariner similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 7990 Removal and Installation Front turn signal lamp 1. Disconnect the front turn signal lamp electrical connector. 2. Rotate the front turn signal lamp bulb holder approximately one-eighth turn counterclockwise and remove from the headlamp assembly. - Separate the bulb from the bulb holder. Side lamp 3. With the vehicle in NEUTRAL, position it on a hoist. 4. Remove the 4 fender splash shield bolts. - To install, tighten to 5 Nm (44 lb-in). 5. Remove the 4 fender splash shield pin-type retainers. 6. Remove the screw and position the fender splash shield aside. 7. Rotate the side lamp bulb holder approximately one-eighth turn counterclockwise and remove from the headlamp assembly. 8. Remove the side lamp bulb from the bulb holder. Front turn signal lamp or side lamp 9. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 8002 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 8003 Interior Lighting Module: Service and Repair Ambient Lighting Module Removal and Installation 1. Remove the center console finish panel. 2. Remove the 2 screws and the ambient lighting module. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 8011 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 8012 Ambient Light Sensor: Service and Repair Light Sensor Removal and Installation 1. Remove the sensor from the instrument panel. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 8016 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 8017 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 8018 Backup Lamp Switch: Service and Repair Reversing Lamp Switch Removal and Installation 1. Disconnect the reversing lamp switch electrical connector. 2. Remove the reversing lamp switch. - To install, tighten to 24 Nm (18 lb-ft). 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Customer Interest for Brake Light Switch: > 09-15-1 > Aug > 09 > ABS/TCS - Traction Control Lamp ON/DTC C1440 Set Brake Light Switch: Customer Interest ABS/TCS - Traction Control Lamp ON/DTC C1440 Set TSB 09-15-1 08/10/09 TRACTION CONTROL LIGHT WITH DTC C1440 - BUILT 6/1/2009-6/10/2009 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built on or between 6/1/2009 to 6/10/2009, may exhibit the traction control light on with DTC code C1440. If the vehicle is operated for an extended period following the illumination of the traction control light, a slight brake drag condition may be observed. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE If the vehicle was built on or between 6/01/2009 to 6/10/2009, and both the traction control light and DTC C1440 are present, then replace the brake pedal switch. If only one is present, and not the other, then proceed with normal diagnostics. Refer to Workshop Manual (WSM), Section 417-01 for brake pedal switch replacement. NOTE DO NOT PRESS OR PULL ON BRAKE PEDAL WHEN INSTALLING OR REMOVING THE STOPLAMP SWITCH OTHERWISE MISADJUSTMENT OR DAMAGE TO THE STOPLAMP SWITCH CAN OCCUR. Parts Block 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 091501A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Replace The Stoplamp Switch. Includes Time To Check For DTCs (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 13480 12 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09-15-1 > Aug > 09 > ABS/TCS - Traction Control Lamp ON/DTC C1440 Set Brake Light Switch: All Technical Service Bulletins ABS/TCS - Traction Control Lamp ON/DTC C1440 Set TSB 09-15-1 08/10/09 TRACTION CONTROL LIGHT WITH DTC C1440 - BUILT 6/1/2009-6/10/2009 FORD: 2009 Escape Hybrid, Escape MERCURY: 2009 Mariner Hybrid, Mariner ISSUE Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built on or between 6/1/2009 to 6/10/2009, may exhibit the traction control light on with DTC code C1440. If the vehicle is operated for an extended period following the illumination of the traction control light, a slight brake drag condition may be observed. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE If the vehicle was built on or between 6/01/2009 to 6/10/2009, and both the traction control light and DTC C1440 are present, then replace the brake pedal switch. If only one is present, and not the other, then proceed with normal diagnostics. Refer to Workshop Manual (WSM), Section 417-01 for brake pedal switch replacement. NOTE DO NOT PRESS OR PULL ON BRAKE PEDAL WHEN INSTALLING OR REMOVING THE STOPLAMP SWITCH OTHERWISE MISADJUSTMENT OR DAMAGE TO THE STOPLAMP SWITCH CAN OCCUR. Parts Block 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 091501A 2009 Escape, Escape 0.3 Hr. Hybrid, Mariner, Mariner Hybrid: Replace The Stoplamp Switch. Includes Time To Check For DTCs (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 13480 12 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 8032 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 8033 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 8034 Brake Light Switch: Service and Repair Stoplamp Switch Removal and Installation NOTICE: Do not press or pull on brake pedal when installing or removing the stoplamp switch otherwise misadjustment or damage to the stoplamp switch could occur. 1. Disconnect the stoplamp switch electrical connector. 2. Rotate the stoplamp switch clockwise approximately one-eighth turn and remove the stoplamp switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Console Lamp Switch > Component Information > Service and Repair Console Lamp Switch: Service and Repair Ambient Lighting Switch Removal and Installation 1. Remove the floor console finish panel. - Disconnect the electrical connector. 2. Squeeze the retaining tabs and remove the ambient lighting switch. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 8041 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 8045 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 8048 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 8049 Headlamp Dimmer Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 8050 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 8051 Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation 1. Remove the steering column opening trim. 2. Remove the 3 lower steering column shroud screws. 3. Remove the upper and lower steering column shrouds. 4. Remove the 2 multifunction switch screws. 5. Disconnect the multifunction switch electrical connector and remove the switch. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8055 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8056 Headlamp Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8057 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8058 Headlamp Switch: Service and Repair Headlamp Switch Removal and Installation 1. Remove the instrument panel side finish panel. 2. NOTE: The headlamp switch is removed by pushing from behind. Release the tabs and remove the headlamp switch. - Disconnect the electrical connectors. 3. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations > Page 8062 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8066 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8067 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8068 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation 1. Remove the steering column opening trim. 2. Remove the 3 lower steering column shroud screws. 3. Remove the upper and lower steering column shrouds. 4. Remove the 2 multifunction switch screws. 5. Disconnect the multifunction switch electrical connector and remove the switch. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions Introduction 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 diagrams 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 that 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. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set 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. 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 a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8073 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". 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, numbered and named. Fuse and Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8074 relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8075 Power and Ground Distribution Diagrams contains the diagram that shows 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 component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information 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. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8076 found on the vehicle. A brief written description of the location is given, along with a reference to the component location 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, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8077 Symbols Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8078 Symbols (Part 1) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8079 Symbols (Part 2) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8080 Symbols (Part 3) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8081 Symbols (Part 4) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8082 Symbols (Part 5) Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8083 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 as shown in each illustration. NOTE: Several components, such as the 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8084 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 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. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8085 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 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8086 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 - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8087 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. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. 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 (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8088 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8089 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8090 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8091 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8092 Tail Lamp: Connector Views Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8093 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8094 Tail Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-1 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8095 Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Special Tools Used With Diagnostics Trailer Lamps Principles of Operation Trailer Lamps Principles of Operation The trailer lamps are supplied power by the trailer tow park lamp relay, the LH trailer tow stop/turn relay and the RH trailer tow stop/turn relay. They are energized to correspond with the exterior lighting functions of the vehicle. A common ground is provided to the trailer tow connector for the trailer lamps. Inspection and Verification Trailer Lamps Inspection and Verification 1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. 3. Visually inspect for obvious signs of electrical damage. Visual Inspection Chart 4. If the concern is not visually evident, verify the symptom. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8100 Trailer Lamps: Symptom Related Diagnostic Procedures Trailer Lamps Symptom Chart Symptom Chart Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8101 Trailer Lamps: Pinpoint Tests Pinpoint Test Y: The Trailer Lamps Are Inoperative - All Trailer Lamps Pinpoint Tests Pinpoint Test Y: The Trailer Lamps Are Inoperative - All Refer to Wiring Diagram Set 95 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The trailer tow connector receives ground through circuits RAT08 (WH) and GD149 (BK/GY) for all of the trailer lamps. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE - ALL NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- Y1 CHECK CIRCUITS RAT08 (WH) AND GD149 (BK/GY) FOR AN OPEN - Disconnect: Trailer Tow C439. - Disconnect: Negative Battery Cable. - Measure the resistance between the trailer tow C439-4, circuit RAT08 (WH), harness side and ground. - Is the resistance less than 5 ohms? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No REPAIR circuit RAT08 (WH) or circuit GD149 (BK/GY) for an open. TEST the system for normal operation. ------------------------------------------------Pinpoint Test Z: The Individual Trailer Lamp Is Inoperative - Trailer Stop/Turn Lamp Trailer Lamps Pinpoint Tests Pinpoint Test Z: The Individual Trailer Lamp Is Inoperative - Trailer Stop/Turn Lamp Refer to Wiring Diagram Set 95 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Battery Junction Box (BJB) fuse 14 (15A) supplies voltage to the LH and RH trailer tow stop/turn relays. The trailer tow stop/turn relay coils are Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8102 grounded through circuit GD120 (BK/GN). The trailer tow LH stop/turn relay coil receives voltage from circuit CLS18 (GY/BN) when the vehicle LH rear stoplamp is illuminated. When the trailer tow LH stop/turn relay is energized, voltage is routed to the trailer tow connector through circuit CAT06 (YE). The trailer tow RH stop/turn relay coil receives voltage through circuit CLS19 (VT/OG) when the vehicle RH rear stoplamp is illuminated. When the trailer tow RH stop/turn relay is energized, voltage is routed to the trailer tow connector through circuit CAT09 (GN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow stop/turn relay - Trailer PINPOINT TEST Z: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - TRAILER STOP/TURN LAMP NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- Z1 CHECK CIRCUIT CAT06 (YE) OR CIRCUIT CAT09 (GN) FOR VOLTAGE - Ignition OFF. - Disconnect: Trailer Tow C439. - For the LH trailer stop/turn lamp, while applying the brake pedal, measure the voltage between the trailer tow C439-2, circuit CAT06 (YE), harness side and ground. - For the RH trailer stop/turn lamp, while applying the brake pedal, measure the voltage between the trailer tow C439-1, circuit CAT09 (GN), harness side and ground. - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No GO to Z2. ------------------------------------------------- Z2 CHECK THE TRAILER TOW STOP/TURN RELAY - Disconnect: Suspect Trailer Tow Stop/Turn Relay. - Substitute a know good relay. - For the LH trailer stop/turn lamp, while applying the brake pedal, measure the voltage between the trailer tow C439-2, circuit CAT06 (YE), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8103 - For the RH trailer stop/turn lamp, while applying the brake pedal, measure the voltage between the trailer tow C439-1, circuit CAT09 (GN), harness side and ground. - Is the voltage greater than 10 volts? Yes REMOVE the known good relay. INSTALL a new trailer tow stop/turn relay. TEST the system for normal operation. No REMOVE the known good relay. GO to Z3. ------------------------------------------------- Z3 CHECK CIRCUIT CLS18 (GY/BN) OR CIRCUIT CLS19 (VT/OG) FOR AN OPEN - While applying the brake pedal, measure the voltage between the trailer tow LH stop/turn relay pin 2, circuit CLS18 (GY/BN), BJB face side and ground; or between the trailer tow RH stop/turn relay pin 2, circuit CLS19 (VT/OG), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to Z4. No REPAIR the circuit in question for an open. TEST the system for normal operation. ------------------------------------------------- Z4 CHECK CIRCUIT SBB14 (BN/RD) FOR AN OPEN - Measure the voltage between the trailer tow LH stop/turn relay pin 3, circuit SBB14 (BN/RD), BJB face side and ground; or between the trailer tow RH stop/turn relay pin 3, circuit SBB14 (BN/RD), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to Z5. No Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8104 VERIFY the BJB fuse 14 (15A) is OK. If OK, REPAIR circuit SBB14 (BN/RD) for an open. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- Z5 CHECK CIRCUIT GD120 (BK/GN) FOR AN OPEN - Disconnect: Negative Battery Cable. - Measure the resistance between the trailer tow LH turn relay pin 1, circuit GD120 (BK/GN), BJB face side and ground; or between the trailer tow RH turn relay pin 1, circuit GD120 (BK/GN), BJB face side and ground. - Is the resistance less than 5 ohms? Yes REPAIR circuit CAT06 (YE) (LH trailer stop/turn) or circuit CAT09 (GN) (RH trailer stop/turn) for an open. TEST the system for normal operation. No REPAIR circuit GD120 (BK/GN) for an open. TEST the system for normal operation. ------------------------------------------------Pinpoint Test AA: The Trailer Lamps Are Inoperative - Trailer Parking Lamps Trailer Lamps Pinpoint Tests Pinpoint Test AA: The Trailer Lamps Are Inoperative - Trailer Parking Lamps Refer to Wiring Diagram Set 95 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The trailer tow parking lamp relay coil receives voltage through circuit CLS30 (VT/WH) when the vehicle parking lamps are illuminated. The trailer tow parking lamp relay coil is grounded through circuit GD120 (BK/GN). The Battery Junction Box (BJB) fuse 8 (20A) supplies voltage to the trailer tow parking lamp relay switch side. When the trailer tow parking lamp relay is energized, the voltage is routed to the trailer tow connector through circuit CAT11 (BN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow parking lamp relay - Trailer PINPOINT TEST AA: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER PARKING LAMPS NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- AA1 CHECK CIRCUIT CAT11 (BN) FOR VOLTAGE - Ignition OFF. - Disconnect: Trailer Tow C439. - Place the headlamp switch in the PARKING LAMPS ON position. - Measure the voltage between the trailer tow C439-3, circuit CAT11 (BN), harness side and ground. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8105 - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No GO to AA2. ------------------------------------------------- AA2 CHECK THE TRAILER TOW PARKING LAMP RELAY - Place the headlamp switch in the OFF position. - Disconnect: Trailer Tow Parking Lamp Relay. - Substitute a known good relay. - Measure the voltage between the trailer tow C439-3, circuit CAT11 (BN), harness side and ground. - Is the voltage greater than 10 volts? Yes REMOVE the known good relay. INSTALL a new trailer tow parking lamp relay. TEST the system for normal operation. No REMOVE the known good relay. GO to AA3. ------------------------------------------------- AA3 CHECK CIRCUIT CLS30 (VT/WH) FOR AN OPEN - Place the headlamp switch in the PARKING LAMPS ON position. - Measure the voltage between the trailer tow parking lamp relay pin 2, circuit CLS30 (VT/WH), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to AA4. No REPAIR circuit CLS30 (VT/WH) for an open. TEST the system for normal operation. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8106 ------------------------------------------------- AA4 CHECK THE SBB08 (VT/RD) FOR AN OPEN - Place the headlamp switch in the OFF position. - Measure the voltage between the trailer tow parking lamp relay pin 3, circuit SBB08 (VT/RD), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to AA5. No VERIFY the BJB fuse 8 (20A) is OK. If OK, REPAIR circuit SBB08 (VT/RD) for an open. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- AA5 CHECK CIRCUIT GD120 (BK/GN) FOR AN OPEN - Disconnect: Negative Battery Cable. - Measure the resistance between the trailer tow parking lamp relay pin 1, circuit GD120 (BK/GN), BJB face side and ground. - Is the resistance less than 5 ohms? Yes REPAIR circuit CAT11 (BN) for an open. TEST the system for normal operation. No REPAIR circuit GD120 (BK/GN) for an open. TEST the system for normal operation. ------------------------------------------------Pinpoint Test AB: The Trailer Lamps Are On Continuously Trailer Lamps Pinpoint Tests Pinpoint Test AB: The Trailer Lamps Are On Continuously Refer to Wiring Diagram Set 95 (Escape/Mariner, Escape Hybrid/Mariner Hybrid), Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation - Trailer Tow Turn/Stoplamp Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8107 The trailer tow LH stop/turn relay coil receives voltage through circuit CLS18 (GY/BN) when the vehicle LH rear stoplamp is illuminated. When the trailer tow LH stop/turn relay is energized, voltage is routed to the trailer tow connector through circuit CAT06 (YE). The trailer tow RH stop/turn relay coil receives voltage through circuit CLS19 (VT/OG) when the vehicle RH rear stoplamp is illuminated. When the trailer tow RH stop/turn relay is energized, voltage is routed to the trailer tow connector through circuit CAT09 (GN). Trailer Tow Parking The trailer tow parking lamp relay coil receives voltage through circuit CLS30 (VT/WH) when the vehicle parking lamps are illuminated. When the trailer tow parking lamp relay is energized, voltage is routed to the trailer tow connector through circuit CAT11 (BN). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer tow relay - Trailer PINPOINT TEST AB: THE TRAILER LAMPS ARE ON CONTINUOUSLY ------------------------------------------------- AB1 CHECK FOR VOLTAGE AT THE TRAILER TOW CONNECTOR - Ignition OFF. - Disconnect: Trailer Tow C439. - Ignition ON. - Measure the voltage the between trailer tow connector, harness side and ground as follows: - Is any voltage present? Yes GO to AB2. No The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. ------------------------------------------------- AB2 CHECK THE SUSPECT RELAY - Ignition OFF. - Disconnect: Suspect Trailer Tow Relay. - Carry out the component test for the suspect trailer tow relay. - Is the trailer tow relay OK? Yes REPAIR circuit CAT06 (YE) (LH turn), circuit CAT09 (GN) (RH turn), or circuit CAT11 (BN) (parking lamps) for a short to voltage. TEST the system for normal operation. No Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8108 INSTALL a new turn trailer tow relay. TEST the system for normal operation. ------------------------------------------------- Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair Turn Signal Bulb: Service and Repair Side Lamp/Front Turn Signal Lamp Bulb Side Lamp (Escape) Front Turn Signal Lamp Bulb NOTE: Escape shown, Mariner similar. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Page 8114 Removal and Installation Front turn signal lamp 1. Disconnect the front turn signal lamp electrical connector. 2. Rotate the front turn signal lamp bulb holder approximately one-eighth turn counterclockwise and remove from the headlamp assembly. - Separate the bulb from the bulb holder. Side lamp 3. With the vehicle in NEUTRAL, position it on a hoist. 4. Remove the 4 fender splash shield bolts. - To install, tighten to 5 Nm (44 lb-in). 5. Remove the 4 fender splash shield pin-type retainers. 6. Remove the screw and position the fender splash shield aside. 7. Rotate the side lamp bulb holder approximately one-eighth turn counterclockwise and remove from the headlamp assembly. 8. Remove the side lamp bulb from the bulb holder. Front turn signal lamp or side lamp 9. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 8118 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 8119 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 8120 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation 1. Remove the steering column opening trim. 2. Remove the 3 lower steering column shroud screws. 3. Remove the upper and lower steering column shrouds. 4. Remove the 2 multifunction switch screws. 5. Disconnect the multifunction switch electrical connector and remove the switch. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left > Page 8125 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Control Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Control Switch > Page 8140 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Control Switch > Page 8141 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Control Switch > Page 8142 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Control Switch Power Window Switch: Diagrams Master Window Control Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Control Switch > Page 8145 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Control Switch > Page 8146 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Control Switch > Page 8147 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Control Switch > Page 8148 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 8151 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 8152 Power Window Switch: Testing and Inspection Window Control Switch, Passenger Side Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 8153 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 8154 Power Window Switch: Testing and Inspection Window Control Switch, Left Rear Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 8155 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 8156 Power Window Switch: Service and Repair Window Control Switch Removal and Installation NOTE: LH front window control switch shown, all others similar. 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 window control switch bezel from the door trim panel. 3. Release the locking tabs and remove the window control switch from the bezel. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Glass, Frames and Mechanisms - Exploded View, Front Door 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair Glass, Frames and Mechanisms - Exploded View, Rear Door 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Control Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Control Switch > Page 8169 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Control Switch > Page 8170 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Control Switch > Page 8171 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Control Switch Power Window Switch: Diagrams Master Window Control Switch Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Control Switch > Page 8174 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Control Switch > Page 8175 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Control Switch > Page 8176 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Control Switch > Page 8177 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) 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 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 8180 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 8181 Power Window Switch: Testing and Inspection Window Control Switch, Passenger Side Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 8182 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 8183 Power Window Switch: Testing and Inspection Window Control Switch, Left Rear Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 8184 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 8185 Power Window Switch: Service and Repair Window Control Switch Removal and Installation NOTE: LH front window control switch shown, all others similar. 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 window control switch bezel from the door trim panel. 3. Release the locking tabs and remove the window control switch from the bezel. 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched Front Door Window Glass Weatherstrip: Customer Interest Body - Front/Rear Door Window Noise/Glass Scratched TSB 11-2-15 02/28/11 WINDOW SQUEAK NOISE AND/OR VERTICAL WINDOW GLASS SCRATCH - BUILT ON OR BEFORE 8/13/2010 FORD: 2008-2011 Escape MERCURY: 2008-2011 Mariner This article supersedes TSB 10-25-5 to update the Part List. ISSUE Some 2008-2011 Escape and Mariner vehicles built on or before 8/13/2010 may exhibit a front and/or rear window glass squeak noise with or without side window vertical window glass scratch. This may be due to a tolerance stack up condition and/or incorrect door flange adjustment. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Fully lower the affected window glass. 2. Remove the exterior door glass weatherstrip. Refer to Workshop Manual (WSM), Section 501-11 (Exploded View). 3. Fully raise the window glass. 4. Measure the distance from the inside edge of the weatherstrip flange to the outside sur[ace of the window glass. Is the distance within specification range of 1/4" (6 mm) to 3/8" (10 mm)? a. Yes - Proceed to Step 5. b. No - Using a suitable tool, evenly adjust the flange into specification. Proceed to Step 5. 5. Inspect the side window glass for evidence of vertical scratches. Are scratches present? a. Yes - Replace the affected side window glass and exterior door glass weatherstrip. Refer to WSM, Section 501-11. b. No - Replace the affected exterior door glass weatherstrip. Refer to WSM, Section 501-11. 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 110215A 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 110215B 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 8196 With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215C 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215D 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors 110215E 2008-2011 Escape, 0.5 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 11021SF 2008-2011 Escape, 1.0 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215G 2008-2011 Escape, 0.8 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215H 2008-2011 Escape, 1.5 Hrs. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 7821453 41 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 8197 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 10-25-4 > Dec > 10 > Body - Front Door Window Exterior Weatherstrip Deformed Front Door Window Glass Weatherstrip: Customer Interest Body - Front Door Window Exterior Weatherstrip Deformed TSB 10-25-4 12/23/10 FRONT EXTERIOR DOOR GLASS WEATHERSTRIP DEFORMED OR LIFTING - BUILT ON OR BEFORE 517/2010 12/23/10 FORD: 008-2010 Escape MERCURY: 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 5/7/2010 may exhibit the front exterior door glass weatherstrip deformed and/or lifting up from the door flange. This may be due to a lack of retention between the door glass weatherstrip and flange. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove affected front exterior door glass weatherstrip. Reference Workshop Manual (WSM), Section 501-11 Glass, Frames, and Mechanisms Exploded View. 2. Apply a strip of 3M(TM) Safety-Walk(TM) Slip-Resistant General Purpose Tapes, or similar (obtained locally) to the outer flange surface at the center of the door. Cut grip tape to approximately 2.5" X .5" (64 mm X 13 mm). (Figure 1) 3. Install new revised exterior door glass weatherstrip. Reference WSM, Section 501-11 Glass, Frames, and Mechanisms - Exploded View. 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 102504A 2008-2010 Escape, 0.2 Hr. Mariner: Replace One Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 10-25-4 > Dec > 10 > Body - Front Door Window Exterior Weatherstrip Deformed > Page 8202 Exterior Door Glass Weather Strip Includes Time To Install Grip Tape (Do Not Use With Any Other Labor Operations) 102504B 2008-2010 Escape, 0.3 Hr. Mariner: Replace Both Exterior Door Glass Weather Strips Includes Time To Install Grip Tape (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7821453 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched Front Door Window Glass Weatherstrip: All Technical Service Bulletins Body - Front/Rear Door Window Noise/Glass Scratched TSB 11-2-15 02/28/11 WINDOW SQUEAK NOISE AND/OR VERTICAL WINDOW GLASS SCRATCH - BUILT ON OR BEFORE 8/13/2010 FORD: 2008-2011 Escape MERCURY: 2008-2011 Mariner This article supersedes TSB 10-25-5 to update the Part List. ISSUE Some 2008-2011 Escape and Mariner vehicles built on or before 8/13/2010 may exhibit a front and/or rear window glass squeak noise with or without side window vertical window glass scratch. This may be due to a tolerance stack up condition and/or incorrect door flange adjustment. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Fully lower the affected window glass. 2. Remove the exterior door glass weatherstrip. Refer to Workshop Manual (WSM), Section 501-11 (Exploded View). 3. Fully raise the window glass. 4. Measure the distance from the inside edge of the weatherstrip flange to the outside sur[ace of the window glass. Is the distance within specification range of 1/4" (6 mm) to 3/8" (10 mm)? a. Yes - Proceed to Step 5. b. No - Using a suitable tool, evenly adjust the flange into specification. Proceed to Step 5. 5. Inspect the side window glass for evidence of vertical scratches. Are scratches present? a. Yes - Replace the affected side window glass and exterior door glass weatherstrip. Refer to WSM, Section 501-11. b. No - Replace the affected exterior door glass weatherstrip. Refer to WSM, Section 501-11. 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 110215A 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 110215B 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 8208 With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215C 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215D 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors 110215E 2008-2011 Escape, 0.5 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 11021SF 2008-2011 Escape, 1.0 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215G 2008-2011 Escape, 0.8 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215H 2008-2011 Escape, 1.5 Hrs. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 7821453 41 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 8209 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-25-4 > Dec > 10 > Body - Front Door Window Exterior Weatherstrip Deformed Front Door Window Glass Weatherstrip: All Technical Service Bulletins Body - Front Door Window Exterior Weatherstrip Deformed TSB 10-25-4 12/23/10 FRONT EXTERIOR DOOR GLASS WEATHERSTRIP DEFORMED OR LIFTING - BUILT ON OR BEFORE 517/2010 12/23/10 FORD: 008-2010 Escape MERCURY: 2008-2010 Mariner ISSUE Some 2008-2010 Escape and Mariner vehicles built on or before 5/7/2010 may exhibit the front exterior door glass weatherstrip deformed and/or lifting up from the door flange. This may be due to a lack of retention between the door glass weatherstrip and flange. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove affected front exterior door glass weatherstrip. Reference Workshop Manual (WSM), Section 501-11 Glass, Frames, and Mechanisms Exploded View. 2. Apply a strip of 3M(TM) Safety-Walk(TM) Slip-Resistant General Purpose Tapes, or similar (obtained locally) to the outer flange surface at the center of the door. Cut grip tape to approximately 2.5" X .5" (64 mm X 13 mm). (Figure 1) 3. Install new revised exterior door glass weatherstrip. Reference WSM, Section 501-11 Glass, Frames, and Mechanisms - Exploded View. 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 102504A 2008-2010 Escape, 0.2 Hr. Mariner: Replace One Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-25-4 > Dec > 10 > Body - Front Door Window Exterior Weatherstrip Deformed > Page 8214 Exterior Door Glass Weather Strip Includes Time To Install Grip Tape (Do Not Use With Any Other Labor Operations) 102504B 2008-2010 Escape, 0.3 Hr. Mariner: Replace Both Exterior Door Glass Weather Strips Includes Time To Install Grip Tape (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7821453 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass Weatherstrip: > 10-13-1 > Jul > 10 > Wipers/Washers - Washer Nozzles Leak Fluid Onto Hood Check Valve: All Technical Service Bulletins Wipers/Washers - Washer Nozzles Leak Fluid Onto Hood TSB 10-13-1 07/19/10 WASHER NOZZLES LEAKING FLUID ONTO HOOD WHILE DRIVING FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner This article supersedes TSB 10-12-5 to update the Part List ISSUE Some 2008-2010 Escape and Mariner vehicles may exhibit the washer nozzles leaking washer fluid onto the hood while driving. A service kit is now available for this condition. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Install check valves and elbows to the hood hose. Add check valve to liftgate hose. Reverse washer pump motor polarity and swap hoses at the pump. Refer to the instruction sheets included in the kit. Parts Block 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 101301A 2008-2010 Escape, 0.9 Hr. Mariner: Install Service Kit Includes Time To Remove And Install The High Mount Stop Lamp (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 17K605 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door Front Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Front Door Glass, Frames and Mechanisms - Exploded View, Front Door 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 8227 Front Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Front Door Glass Top Run - Front Removal and Installation 1. Remove the front door window glass. For additional information, refer to Window Glass - Front Door See: Service and Repair/Window Glass Front Door. 2. Remove the front door interior sail panel. - If equipped, disconnect the speaker electrical connector. 3. Remove the 2 front door glass top run bolts. - To install tighten to 6 Nm (53 lb-in). 4. Remove the front door glass top run. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair Window Glass - Liftgate Removal and Installation 1. Open the liftgate window glass. 2. Remove the 2 liftgate window glass nut access covers. 3. Through the RH access, disconnect the liftgate window glass electrical harness connector. 4. Disconnect the LH heated window grid wire electrical connector. 5. NOTE: An assistant may be needed to carry out this step. Disconnect the 2 liftgate window glass cylinders. 1. Slide the spring retainer to the end of the socket. 2. Disconnect the socket from the ball stud. 6. NOTE: An assistant may be needed to carry out this step. Remove the 2 liftgate window glass hinge nuts and the liftgate window glass. - To install, tighten to 11 Nm (97 lb-in). 7. To install, reverse the removal procedure. - Transfer components as necessary. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair Quarter Window Glass: Service and Repair Window Glass - Rear Quarter Removal LH rear quarter window glass 1. If equipped, remove the auxiliary climate control housing. 2. If equipped, remove the bolt and the auxiliary climate control upper housing bracket. All rear quarter window glass 3. Remove the headliner. 4. Before cutting the urethane adhesive, remove dirt and other foreign material from the pinch weld area. - Use a clean shop towel or oil-free, compressed air. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 8234 5. Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool when cutting. 6. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer or otherwise damage the pinch weld during glass removal. NOTE: Locating pins 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 pins. Using the Deluxe Windshield Removal 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. 7. Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld. Installation All rear quarter window glass 1. Dry fit the rear quarter window glass, making alignment marks with tape or non-staining grease pencil. 2. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s). NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following manufacturer's instructions. Use the same brand pinch weld primer, glass primer and urethane adhesive. Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm (0.04 in to 0.08 in) base of original equipment urethane adhesive on the pinchweld. 3. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the existing urethane adhesive. Remove any foreign material or water that may have entered during glass removal. 4. If installing the original rear quarter window glass, remove the excess urethane adhesive. 5. Clean the inside of the rear quarter window glass with glass cleaner. 6. NOTICE: If installing a LH rear quarter window on the Escape Hybrid, do not apply urethane glass prep to the polycarbonate vent of the window assembly. NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and glass primer. Do not mix different brands of urethane adhesive and glass primer. For additional information, refer to the Material Chart in this procedure. If installing a new rear window glass, apply glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 8235 7. Cut the urethane adhesive applicator tip to specification. 8. NOTE: The rear quarter glass must be positioned within 10 minutes of applying the urethane adhesive. NOTE: Use caution when applying urethane adhesive. Apply to the outside edges of locating pins on the glass surface. NOTE: Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane adhesive with less effort and a continuous bead. Apply a bead of urethane adhesive starting at the bottom and work around to the sides of the rear quarter window glass to specification, making sure there are no gaps in the bead. 9. WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s). NOTICE: Before positioning the rear quarter window glass, open vehicle windows to prevent the air pressure of closing doors from affecting the urethane adhesive bond. Install the rear quarter window glass, aligning it to the marks previously made. 10. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks. After the urethane adhesive has cured, check for water leaks and add urethane adhesive where needed. 11. If necessary, remove excess urethane adhesive from the exterior surface of the quarter window glass. 12. Install the headliner. LH quarter window glass 13. If equipped, install the auxiliary climate control upper housing bracket and the bolt. 14. If equipped, install the auxiliary climate control housing. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched Rear Door Window Glass Weatherstrip: Customer Interest Body - Front/Rear Door Window Noise/Glass Scratched TSB 11-2-15 02/28/11 WINDOW SQUEAK NOISE AND/OR VERTICAL WINDOW GLASS SCRATCH - BUILT ON OR BEFORE 8/13/2010 FORD: 2008-2011 Escape MERCURY: 2008-2011 Mariner This article supersedes TSB 10-25-5 to update the Part List. ISSUE Some 2008-2011 Escape and Mariner vehicles built on or before 8/13/2010 may exhibit a front and/or rear window glass squeak noise with or without side window vertical window glass scratch. This may be due to a tolerance stack up condition and/or incorrect door flange adjustment. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Fully lower the affected window glass. 2. Remove the exterior door glass weatherstrip. Refer to Workshop Manual (WSM), Section 501-11 (Exploded View). 3. Fully raise the window glass. 4. Measure the distance from the inside edge of the weatherstrip flange to the outside sur[ace of the window glass. Is the distance within specification range of 1/4" (6 mm) to 3/8" (10 mm)? a. Yes - Proceed to Step 5. b. No - Using a suitable tool, evenly adjust the flange into specification. Proceed to Step 5. 5. Inspect the side window glass for evidence of vertical scratches. Are scratches present? a. Yes - Replace the affected side window glass and exterior door glass weatherstrip. Refer to WSM, Section 501-11. b. No - Replace the affected exterior door glass weatherstrip. Refer to WSM, Section 501-11. 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 110215A 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 110215B 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 8245 With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215C 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215D 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors 110215E 2008-2011 Escape, 0.5 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 11021SF 2008-2011 Escape, 1.0 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215G 2008-2011 Escape, 0.8 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215H 2008-2011 Escape, 1.5 Hrs. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 7821453 41 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 8246 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched Rear Door Window Glass Weatherstrip: All Technical Service Bulletins Body - Front/Rear Door Window Noise/Glass Scratched TSB 11-2-15 02/28/11 WINDOW SQUEAK NOISE AND/OR VERTICAL WINDOW GLASS SCRATCH - BUILT ON OR BEFORE 8/13/2010 FORD: 2008-2011 Escape MERCURY: 2008-2011 Mariner This article supersedes TSB 10-25-5 to update the Part List. ISSUE Some 2008-2011 Escape and Mariner vehicles built on or before 8/13/2010 may exhibit a front and/or rear window glass squeak noise with or without side window vertical window glass scratch. This may be due to a tolerance stack up condition and/or incorrect door flange adjustment. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Fully lower the affected window glass. 2. Remove the exterior door glass weatherstrip. Refer to Workshop Manual (WSM), Section 501-11 (Exploded View). 3. Fully raise the window glass. 4. Measure the distance from the inside edge of the weatherstrip flange to the outside sur[ace of the window glass. Is the distance within specification range of 1/4" (6 mm) to 3/8" (10 mm)? a. Yes - Proceed to Step 5. b. No - Using a suitable tool, evenly adjust the flange into specification. Proceed to Step 5. 5. Inspect the side window glass for evidence of vertical scratches. Are scratches present? a. Yes - Replace the affected side window glass and exterior door glass weatherstrip. Refer to WSM, Section 501-11. b. No - Replace the affected exterior door glass weatherstrip. Refer to WSM, Section 501-11. 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 110215A 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 110215B 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 8252 With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215C 2008-2011 Escape, 0.2 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215D 2008-2011 Escape, 0.3 Hr. Mariner: Measure And Adjust Flange, Install New Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors 110215E 2008-2011 Escape, 0.5 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Front Door 11021SF 2008-2011 Escape, 1.0 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Front Doors 110215G 2008-2011 Escape, 0.8 Hr. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) One (1) Rear Door 110215H 2008-2011 Escape, 1.5 Hrs. Mariner: Measure And Adjust Flange, Install New Door Glass, And Exterior Door Glass Weatherstrip (Do Not Use With Any Labor Operations Outside Of This Article) Both (2) Rear Doors DEALER CODING CONDITION BASIC PART NO. CODE 7821453 41 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 11-2-15 > Feb > 11 > Body - Front/Rear Door Window Noise/Glass Scratched > Page 8253 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Window Glass Weatherstrip: > 10-13-1 > Jul > 10 > Wipers/Washers - Washer Nozzles Leak Fluid Onto Hood Windshield Washer Spray Nozzle: All Technical Service Bulletins Wipers/Washers - Washer Nozzles Leak Fluid Onto Hood TSB 10-13-1 07/19/10 WASHER NOZZLES LEAKING FLUID ONTO HOOD WHILE DRIVING FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner This article supersedes TSB 10-12-5 to update the Part List ISSUE Some 2008-2010 Escape and Mariner vehicles may exhibit the washer nozzles leaking washer fluid onto the hood while driving. A service kit is now available for this condition. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Install check valves and elbows to the hood hose. Add check valve to liftgate hose. Reverse washer pump motor polarity and swap hoses at the pump. Refer to the instruction sheets included in the kit. Parts Block 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 101301A 2008-2010 Escape, 0.9 Hr. Mariner: Install Service Kit Includes Time To Remove And Install The High Mount Stop Lamp (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 17K605 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear Rear Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Rear Door Glass Top Run - Rear Removal and Installation 1. Remove the rear door window regulator. For additional information, refer to Window Regulator Rear Door See: Window Regulator/Rear Door Window Regulator/Service and Repair/Window Regulator - Rear Door. 2. Position the rear door window glass to the full DOWN position. 3. Remove the 2 screws and the rear door exterior sail panel. 4. Remove the interior door glass weatherstrip. 5. Remove the exterior door glass weatherstrip. 6. Remove the rear door glass top run bolt. - To install, tighten to 6 Nm (53 lb-in). 7. Position the rear door window glass down and forward. 8. Remove the rear door glass top run. 9. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear > Page 8266 Rear Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Rear Door Glass, Frames and Mechanisms - Exploded View, Rear Door 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door Front Door Window Regulator: Service and Repair Glass, Frames and Mechanisms - Exploded View, Front Door Glass, Frames and Mechanisms - Exploded View, Front Door 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 8272 Front Door Window Regulator: Service and Repair Window Regulator - Front Door Window Regulator - Front Door Removal and Installation 1. Remove the front door trim panel. 2. Remove the screw and the front door trim panel bracket. 3. Remove the 3 pushpins and pad assembly. 4. NOTE: Do not touch the adhesive surface during removal or installation of the watershield, as re-bonding will be impaired. If additional adhesive is required during installation, apply seam sealer as necessary to completely seal the watershield to the inner door. Position the watershield aside. 5. Connect the window control switch electrical connector. 6. Using the window control switch, lower the front door window glass to gain access to the front door window glass screws. 7. Disconnect the window control switch electrical connector. 8. Remove the 2 front door window glass screws. - To install, tighten to 5 Nm (44 lb-in). 9. Support the front door window glass in the full UP position with tape. 10. Disconnect the front door window motor electrical connector. 11. Remove the front door window regulator and motor bolt. - To install, tighten to 11 Nm (97 lb-in). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 8273 12. Loosen the 2 front door window regulator and motor bolts. - To install, tighten to 11 Nm (97 lb-in). 13. Remove the 2 nuts and the front door window regulator and motor. - To install, tighten to 11 Nm (97 lb-in). 14. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door Rear Door Window Regulator: Service and Repair Glass, Frames and Mechanisms - Exploded View, Rear Door Glass, Frames and Mechanisms - Exploded View, Rear Door 1. For additional information, refer to the procedures. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door > Page 8278 Rear Door Window Regulator: Service and Repair Window Regulator - Rear Door Window Regulator - Rear Door Removal and Installation 1. Remove the rear door trim panel. 2. Remove the screw and the rear door trim panel bracket. 3. NOTE: Do not touch the adhesive surface during removal or installation of the watershield, as re-bonding will be impaired. If additional adhesive is required during installation, apply seam sealer as necessary to completely seal the watershield to the inner door. Position the watershield aside. 4. Connect the window control switch electrical connector. 5. Using the window control switch, lower the rear door window glass to gain access to the rear door window glass screws. 6. Disconnect the window control switch electrical connector. 7. Remove the 2 rear door window glass screws. - To install, tighten to 5 Nm (44 lb-in). 8. Support the rear door window glass in the full UP position with tape. 9. Disconnect the rear door window motor electrical connector. 10. Remove the rear door window regulator and motor bolt. - To install, tighten to 11 Nm (97 lb-in). 11. Loosen the 2 rear door window regulator and motor bolts. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door > Page 8279 - To install, tighten to 11 Nm (97 lb-in). 12. Remove the 2 nuts and the rear door window regulator and motor. - To install, tighten to 6 Nm (53 lb-in). 13. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass Windshield: Service and Repair Windshield Glass Windshield Glass Removal 1. Remove the LH and RH A-pillar trim panels. 2. Remove the 2 windshield side garnish mouldings. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 8284 3. Open the front overhead console door, remove the 2 screws and the overhead console. - If equipped, disconnect the electrical connector. 4. Remove the interior rear view mirror. 5. Remove the LH and RH sun visors and visor clips. - If equipped, disconnect the electrical connectors. 6. Partially lower the front portion of the headliner and block with a suitable material. 7. Remove the cowl panel grille. 8. Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield pinch weld area. - Use a clean shop towel or oil-free, compressed air. 9. Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool when cutting. 10. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer or otherwise damage the pinch weld during glass removal. NOTE: Insert the blade into the Deluxe Windshield Removal Tool so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinch weld and allow a dry fit of the replacement windshield glass. Insert the Deluxe Windshield Removal Tool at the upper center of the windshield glass and work toward the bottom corners. 11. Using The Pumper, distance the windshield glass from the body. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 8285 12. Using the Deluxe Windshield Removal Tool, cut the remaining urethane adhesive and remove the windshield glass. 13. Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld. Installation 1. Dry-fit the new windshield glass on the existing urethane adhesive bead on the pinch weld. - Position the windshield glass on the pinch weld. - Center the windshield glass in the opening. - Adjust the windshield glass stop blocks (if equipped) as needed for best fit. - Make alignment marks with tape or non-staining grease pencil (preferably at the windshield glass stop blocks if equipped) on the windshield glass and the body. 2. After the dry-fit alignment, remove the glass from the windshield opening and place on a stable work surface with the interior side of the glass facing up. 3. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s). NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following manufacturer's instructions. Use the same brand pinch weld, glass primer and urethane adhesive. Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm (0.04 in to 0.08 in) base of original equipment urethane adhesive on the pinchweld. 4. Using a clean shop towel, brush or oil-free, compressed air, clean the pinch weld area around the existing urethane adhesive. Remove any foreign material or water that may have entered during windshield removal. 5. If reinstalling the same windshield glass, remove the windshield moulding and remaining urethane adhesive from the glass leaving a thin layer to bond with the new urethane adhesive bead. 6. Clean the inside of the new windshield glass with glass cleaner. 7. NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and glass primer. Do not mix different brands of urethane adhesive and glass primer. For additional information, refer to the Material Chart in this procedure. If installing a new windshield glass, apply glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry. 8. Cut the urethane adhesive applicator tip to specification. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 8286 9. NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane adhesive. NOTE: Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane adhesive with less effort and a continuous bead. Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld, starting and ending at the bottom of the windshield near the center, make sure there are no gaps in the bead. 10. WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s). NOTICE: Before positioning the windshield glass, open vehicle windows to prevent the air pressure of closing doors from affecting the urethane adhesive bond. Install the windshield glass, aligning it to the marks previously made. 11. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air and water leaks. After the urethane adhesive has cured, check for water leaks and add urethane adhesive where needed. 12. If necessary, remove excess urethane adhesive from the exterior surface of the windshield glass. 13. Install the cowl panel grille. 14. Reposition the front portion of the headliner. 15. Install the LH and RH sun visors and visor clips. - If equipped, connect the electrical connectors. 16. Install the interior rear view mirror. 17. Position the overhead console and install the 2 overhead console screws. - If equipped, connect the electrical connector. 18. Install the 2 windshield side garnish mouldings. 19. Install the LH and RH A-pillar trim panels. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 8287 Windshield: Service and Repair Glass Reseal - Windshield Glass Reseal - Windshield 1. Remove the LH and RH A-pillar trim panels. 2. Remove the 2 windshield side garnish mouldings. 3. Open the front overhead console door, remove the 2 screws and the overhead console. - If equipped, disconnect the electrical connector. 4. Remove the LH and RH sun visors and visor clips. - If equipped, disconnect the electrical connectors. 5. Partially lower the front portion of the headliner and block with a suitable material. 6. Remove the cowl panel grille. 7. Clean the interior and exterior of the windshield glass surface with glass cleaner. 8. Cut the urethane adhesive applicator tip to specification. 9. NOTE: Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane adhesive with less effort and a continuous bead. NOTE: Make sure there are no gaps in the urethane adhesive bead. Apply urethane adhesive over the top of the existing urethane adhesive. - Apply the urethane adhesive to the top and sides of the windshield from the interior of the vehicle. - Apply the urethane adhesive to the bottom of the windshield from the exterior of the vehicle. 10. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks. After the urethane adhesive has cured, check the windshield seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary. 11. Install the cowl panel grille. 12. Position the front portion of the headliner. 13. Install the LH and RH sun visors and visor clips. - If equipped, connect the electrical connectors. 14. Position the overhead console and install the 2 overhead console screws. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 8288 - If equipped, connect the electrical connector. 15. Install the 2 windshield side garnish mouldings. 16. Install the LH and RH A-pillar trim panels. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical Service Bulletins > Customer Interest for Check Valve: > 10-13-1 > Jul > 10 > Wipers/Washers - Washer Nozzles Leak Fluid Onto Hood Check Valve: Customer Interest Wipers/Washers - Washer Nozzles Leak Fluid Onto Hood TSB 10-13-1 07/19/10 WASHER NOZZLES LEAKING FLUID ONTO HOOD WHILE DRIVING FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner This article supersedes TSB 10-12-5 to update the Part List ISSUE Some 2008-2010 Escape and Mariner vehicles may exhibit the washer nozzles leaking washer fluid onto the hood while driving. A service kit is now available for this condition. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Install check valves and elbows to the hood hose. Add check valve to liftgate hose. Reverse washer pump motor polarity and swap hoses at the pump. Refer to the instruction sheets included in the kit. Parts Block 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 101301A 2008-2010 Escape, 0.9 Hr. Mariner: Install Service Kit Includes Time To Remove And Install The High Mount Stop Lamp (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 17K605 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Check Valve: > 10-13-1 > Jul > 10 > Wipers/Washers - Washer Nozzles Leak Fluid Onto Hood Check Valve: All Technical Service Bulletins Wipers/Washers - Washer Nozzles Leak Fluid Onto Hood TSB 10-13-1 07/19/10 WASHER NOZZLES LEAKING FLUID ONTO HOOD WHILE DRIVING FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner This article supersedes TSB 10-12-5 to update the Part List ISSUE Some 2008-2010 Escape and Mariner vehicles may exhibit the washer nozzles leaking washer fluid onto the hood while driving. A service kit is now available for this condition. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Install check valves and elbows to the hood hose. Add check valve to liftgate hose. Reverse washer pump motor polarity and swap hoses at the pump. Refer to the instruction sheets included in the kit. Parts Block 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 101301A 2008-2010 Escape, 0.9 Hr. Mariner: Install Service Kit Includes Time To Remove And Install The High Mount Stop Lamp (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 17K605 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8307 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8308 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8309 Windshield Washer Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8310 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8311 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation 1. Remove the steering column opening trim. 2. Remove the 3 lower steering column shroud screws. 3. Remove the upper and lower steering column shrouds. 4. Remove the 2 multifunction switch screws. 5. Disconnect the multifunction switch electrical connector and remove the switch. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8315 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8316 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8317 Wiper Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8318 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8319 Wiper Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation 1. Remove the steering column opening trim. 2. Remove the 3 lower steering column shroud screws. 3. Remove the upper and lower steering column shrouds. 4. Remove the 2 multifunction switch screws. 5. Disconnect the multifunction switch electrical connector and remove the switch. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair Windshield Washer Hose: Service and Repair Washer Hose Repair NOTE: This procedure may be carried out on rubber hoses only. If a plastic washer hose is leaking, a new washer hose must be installed. 1. Locate and verify the leaking washer hose. 2. Cut the hose cleanly and remove the damaged portion of the washer hose. 3. Install a windshield washer hose adapter between the cut ends of the hose. 4. NOTE: In difficult cases, clamping may be required. Install a segment of 6.4 mm (0.25 in) ID black rubber hose over the ends of the washer hose and clamp both ends of the rubber hose using spring clamps. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 8326 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Washer Pump Windshield Washer Pump: Service and Repair Washer Pump Washer Pump Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the RH front fender splash shield. 3. Disconnect the washer pump electrical connector. 4. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: To prevent damage to the connector, do not use hand tools to remove/install the washer pump hose. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before washer pump removal. Disconnect the washer pump hoses. Gently twist the lock ring until the ring has rotated approximately 90 degrees. - The hose should slide easily out of the connection. - To install, make sure the hoses are fully seated and locked into place. 5. NOTICE: Do not leave the lock ring in the disassembled position. This will weaken the ring and may prevent it from correctly locking in place when reassembled, resulting in a leak. Rotate the lock ring back to the original location. 6. NOTICE: When installing a new washer pump, be careful not to damage the rubber grommet. Remove the washer pump. 7. NOTICE: Do not operate the washer pump prior to filling the windshield washer reservoir. Failure to follow these instructions may result in premature pump failure. To install, reverse the removal procedure. - Fill the windshield washer reservoir with windshield washer fluid. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Washer Pump > Page 8331 Windshield Washer Pump: Service and Repair Washer Pump and Reservoir Washer Pump and Reservoir Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the RH front fender splash shield. 3. Disconnect the washer pump electrical connector. 4. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: To prevent damage to the connector, do not use hand tools to remove/install the washer pump hose. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before removal. Disconnect the washer pump hoses. Gently twist the lock ring until the ring has rotated approximately 90 degrees. - The hose should slide easily out of the connection. - To install, make sure the hoses are fully seated and locked into place. 5. NOTICE: Do not leave the lock ring in the disassembled position. This will weaken the ring and may prevent it from correctly locking in place when reassembled, resulting in a leak. Rotate the lock ring back to the original location. 6. Remove the 2 windshield washer reservoir bolts and the windshield washer reservoir. - To install, tighten to 6 Nm (53 lb-in). 7. NOTICE: Do not operate the washer pump prior to filling the windshield washer reservoir. Failure to follow these instructions may result in premature pump failure. To install, reverse the removal procedure. - Fill the windshield washer reservoir with windshield washer fluid. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair Washer Pump and Reservoir Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the RH front fender splash shield. 3. Disconnect the washer pump electrical connector. 4. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: To prevent damage to the connector, do not use hand tools to remove/install the washer pump hose. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before removal. Disconnect the washer pump hoses. Gently twist the lock ring until the ring has rotated approximately 90 degrees. - The hose should slide easily out of the connection. - To install, make sure the hoses are fully seated and locked into place. 5. NOTICE: Do not leave the lock ring in the disassembled position. This will weaken the ring and may prevent it from correctly locking in place when reassembled, resulting in a leak. Rotate the lock ring back to the original location. 6. Remove the 2 windshield washer reservoir bolts and the windshield washer reservoir. - To install, tighten to 6 Nm (53 lb-in). 7. NOTICE: Do not operate the washer pump prior to filling the windshield washer reservoir. Failure to follow these instructions may result in premature pump failure. To install, reverse the removal procedure. - Fill the windshield washer reservoir with windshield washer fluid. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Technical Service Bulletins > Customer Interest for Windshield Washer Spray Nozzle: > 10-13-1 > Jul > 10 > Wipers/Washers - Washer Nozzles Leak Fluid Onto Hood Windshield Washer Spray Nozzle: Customer Interest Wipers/Washers - Washer Nozzles Leak Fluid Onto Hood TSB 10-13-1 07/19/10 WASHER NOZZLES LEAKING FLUID ONTO HOOD WHILE DRIVING FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner This article supersedes TSB 10-12-5 to update the Part List ISSUE Some 2008-2010 Escape and Mariner vehicles may exhibit the washer nozzles leaking washer fluid onto the hood while driving. A service kit is now available for this condition. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Install check valves and elbows to the hood hose. Add check valve to liftgate hose. Reverse washer pump motor polarity and swap hoses at the pump. Refer to the instruction sheets included in the kit. Parts Block 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 101301A 2008-2010 Escape, 0.9 Hr. Mariner: Install Service Kit Includes Time To Remove And Install The High Mount Stop Lamp (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 17K605 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Washer Spray Nozzle: > 10-13-1 > Jul > 10 > Wipers/Washers - Washer Nozzles Leak Fluid Onto Hood Windshield Washer Spray Nozzle: All Technical Service Bulletins Wipers/Washers - Washer Nozzles Leak Fluid Onto Hood TSB 10-13-1 07/19/10 WASHER NOZZLES LEAKING FLUID ONTO HOOD WHILE DRIVING FORD: 2008-2010 Escape MERCURY: 2008-2010 Mariner This article supersedes TSB 10-12-5 to update the Part List ISSUE Some 2008-2010 Escape and Mariner vehicles may exhibit the washer nozzles leaking washer fluid onto the hood while driving. A service kit is now available for this condition. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Install check valves and elbows to the hood hose. Add check valve to liftgate hose. Reverse washer pump motor polarity and swap hoses at the pump. Refer to the instruction sheets included in the kit. Parts Block 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 101301A 2008-2010 Escape, 0.9 Hr. Mariner: Install Service Kit Includes Time To Remove And Install The High Mount Stop Lamp (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 17K605 07 Disclaimer Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8351 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8352 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8353 Windshield Washer Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8354 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8355 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation 1. Remove the steering column opening trim. 2. Remove the 3 lower steering column shroud screws. 3. Remove the upper and lower steering column shrouds. 4. Remove the 2 multifunction switch screws. 5. Disconnect the multifunction switch electrical connector and remove the switch. 6. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Wiper Blade and Pivot Arm Adjustment - Windshield Wiper Arm: Adjustments Wiper Blade and Pivot Arm Adjustment - Windshield Wiper Blade and Pivot Arm Adjustment - Windshield 1. Cycle and park the windshield wipers. 2. Verify that the RH and LH wiper blades are located at the specified position. 3. NOTE: Make sure there is no mechanical binding in the linkage preventing the wiper arms from returning to the fully parked position. If not within specification, remove the nuts and the windshield wiper pivot arms and reposition them to the correct locations. - To install, tighten to 40 Nm (30 lb-ft). Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Wiper Blade and Pivot Arm Adjustment - Windshield > Page 8360 Wiper Arm: Adjustments Wiper Blade and Pivot Arm Adjustment - Rear Wiper Blade and Pivot Arm Adjustment - Rear 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 it to the correct location. For additional information, refer to Wiper Pivot Arm - Rear See: Service and Repair/Wiper Pivot Arm - Rear. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Windshield Wiper Wiper Arm: Service and Repair Wiper Pivot Arm - Windshield Wiper Wiper Pivot Arm - Windshield Wiper Removal and Installation 1. NOTE: LH shown, RH similar. Remove the 2 wiper pivot arm nuts. - To install, tighten to 40 Nm (30 lb-ft). 2. Remove the LH and RH wiper pivot arms. 3. To install, reverse the removal procedure. - Adjust the wiper pivot arms. For additional information, refer to Wiper Blade and Pivot Arm Adjustment - Windshield See: Adjustments/Wiper Blade and Pivot Arm Adjustment - Windshield. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Windshield Wiper > Page 8363 Wiper Arm: Service and Repair Wiper Mounting Arm and Pivot Shaft Wiper Mounting Arm and Pivot Shaft Removal and Installation 1. Remove the cowl panel grille. 2. Remove the 3 windshield wiper mounting arm and pivot shaft assembly bolts and the windshield wiper mounting arm and pivot shaft assembly. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the windshield wiper motor electrical connector. 4. Remove the wiper motor assembly. For additional information, refer to Wiper Motor - Windshield See: Wiper Motor/Service and Repair/Wiper Motor - Windshield. 5. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Windshield Wiper > Page 8364 Wiper Arm: Service and Repair Wiper Pivot Arm - Rear Wiper Pivot Arm - Rear Removal and Installation 1. Open the wiper pivot arm cover. 2. Remove the pivot arm nut. - To install, tighten to 12 Nm (106 lb-in). 3. Remove the wiper pivot arm. 4. To install, reverse the removal procedure. - Adjust the wiper pivot arms. For additional information, refer to Wiper Blade and Pivot Arm Adjustment - Rear See: Adjustments/Wiper Blade and Pivot Arm Adjustment - Rear. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair Wiper Blade: Service and Repair Wiper Blade - Rear Removal NOTICE: Lifting the wiper arm beyond its maximum angle may result in damage to the wiper arm or the wiper arm heel. NOTICE: Allowing the wiper arm to contact the glass may result in damage to the glass. 1. Hold the wiper arm with one hand close to the wiper arm and wiper blade pivot joint and lift the arm to its maximum angle. 2. Hold the primary structure of the wiper blade with the other hand close to the wiper arm and wiper blade pivot joint. 3. Tightly grip and push on the wiper arm and wiper blade joint from beneath and separate the blade from the arm. Installation 1. Attach the new wiper blade on the wiper arm and press it into place until a snap is heard. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Windshield Wiper Motor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Windshield Wiper Motor > Page 8372 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Windshield Wiper Motor Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Windshield Wiper Motor > Page 8375 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield Wiper Motor: Service and Repair Wiper Motor - Windshield Wiper Motor - Windshield Removal and Installation NOTE: A new wiper motor assembly comes with the linkage arm installed. 1. Remove the windshield wiper mounting arm and pivot shaft. For additional information, refer to Wiper Mounting Arm and Pivot Shaft See: Wiper Arm/Service and Repair/Wiper Mounting Arm and Pivot Shaft. 2. NOTICE: Do not remove the wiper motor linkage arm from the wiper motor assembly. If the arm is removed, the wiper arms may not park in the correct location. Separate the wiper motor linkage arm from the wiper mounting arm and pivot shaft assembly. - Use a suitable tool at the location shown to separate the wiper linkage arm from the wiper mounting arm and pivot shaft assembly. 3. Remove the 3 bolts and the wiper motor. - To install, tighten to 13 Nm (115 lb-in). 4. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 8378 Wiper Motor: Service and Repair Wiper Motor - Rear Window Wiper Motor - Rear Window Removal and Installation 1. Remove the rear pivot arm. For additional information, refer to Wiper Pivot Arm - Rear See: Wiper Arm/Service and Repair/Wiper Pivot Arm Rear. 2. Remove the rear wiper motor shaft nut cover. 3. Remove the rear wiper motor shaft nut. - To install, manually finger-tighten the nut, then tighten to 6 Nm (53 lb-in). 4. Open the liftgate window. 5. Remove the rear wiper motor cover trim panel. 6. Remove the rear wiper motor. 1. Disconnect the electrical connector. 2. Remove the 2 rear window wiper motor nuts. - To install, tighten to 7 Nm (62 lb-in). 3. Remove the rear window wiper motor. 7. To install, reverse the removal procedure. Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8382 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8383 Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8384 Wiper Switch: Testing and Inspection Ford Escape 4wd Workshop Manual (L4-2.5L Hybrid (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8385